System for reducing ink color mixing effects in printer

ABSTRACT

A system for reducing ink color mixing effects in a printer is provided having a printhead having multiple ink color channels mounted to a housing of the printer at a first level, and a plurality of ink supply cartridges mounted to the printer housing so as to be fluidically connected to the printhead and stacked in an array having a plurality of rows defining a plurality of levels which are lower than the first level. The plurality of ink supply cartridges include at least one black ink supply cartridge which supplies black colored ink to a black ink color channel of the printhead. The black ink supply cartridge is disposed at the lowest level defined by the array.

FIELD OF INVENTION

The invention relates to printing systems, printing apparatus andmethods for printing on continuous web media, and in particularcontinuous label web media, and to the configuration and arrangement ofthe components of such systems and apparatus. The related printingsystems, apparatus and methods include those which distribute fluidwithin a printing environment. In particular, the fluid is a printingfluid, such as ink or ink fixing agent, as is distributed to and from afluid ejection printhead, such as an inkjet printhead. Moreparticularly, fluid distribution to an inkjet media width printhead isprovided. The related printing systems, apparatus and methods alsoinclude those which maintain such a printhead and which handle the mediabefore and after the media is printed on by the printhead.

CO-PENDING APPLICATIONS

The following applications have been filed by the Applicant which relateto the present application:

KPF001US KPF002US KPF003US KPF004US KPF005US KPF006US KPF007US KPF008USKPF009US KPF010US KPF011US KPF012US KPF013US KPF014US KPF015US KPF016USKPF017US KPF018US KPF019US KPF020US KPF021US KPF022US KPF023US KPF024USKPF025US KPF026US KPF027US KPF028US KPF029US KPF030US KPF031US KPF032USKPF033US KPF034US KPF035US KPF036US KPF037US KPF038US KPF039US KPF040USKPF041US KPF042US KPF043US KPF044US KPF045US KPF046US KPF047US KPF048USKPF049US KPF050US KPM001US KPM002US KPM003US KPM004US KPM005US KPM006USKPM007US KPM008US KPM009US KPM010US KPM011US KPM012US KPM013US KPM014USKPM015US KPM016US KPM017US KPM018US KPM019US KPM020US LNP001US LNP002USLNP003US LNP005US LNP006US LNP007US LNP008US LNP009US LNP010US LNP011USLNP012US LNP013US LNP014US LNP015US LNP016US LNP017US LNP018US LNP019USThe disclosures of these co-pending applications are incorporated hereinby reference. The above applications have been identified by theirfiling docket number, which will be substituted with the correspondingapplication number, once assigned.

CROSS REFERENCES

The following patents or patent applications filed by the applicant orassignee of the present invention are hereby incorporated bycross-reference.

6,276,850 6,443,555 7,215,441 6,906,778 6,688,528 6,641,317 7,155,3957,118,481 6,750,901 6,496,654 7,021,745 6,712,453 6,428,147 6,416,1706,402,300 6,464,340 6,612,687 6,412,912 6,447,099 6,505,913 7,249,1086,566,858 6,442,525 09/517,384 09/505,951 6,374,354 7,246,098 6,816,9686,757,832 6,334,190 6,745,331 7,249,109 10/940,653 10/942,858 7,286,1696,985,207 6,878,299 10/780,625 10/831,234 10/831,233 7,246,897 7,077,51510/831,235 10/853,336 6,913,875 11/012,024 11/011,925 6,710,4576,530,339 6,238,044 11/003,786 11/003,463 11/003,701 11/003,68311/003,464 7,284,820 11/293,800 11/482,975 11/482,970 11/482,96811/482,972 11/482,971 11/482,969 6,431,577 6,471,331 11/097,26611/685,084 11/740,925 11/763,444 7,206,654 6,786,420 6,948,661 7,073,71311/518,238 7,032,899 11/084,237 6,350,023 11/246,676 11/246,70711/482,958 11/482,955 11/482,962 11/482,963 11/482,956 11/482,95411/482,974 11/482,957 11/482,987 11/482,959 11/482,960 11/482,96111/482,964 11/482,965 11/482,976 11/482,973 11/495,815 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6,390,6056,322,195 6,426,014 6,340,453 6,317,399 6,595,624 6,417,757 7,095,3096,817,700 6,425,971 6,383,833 6,746,105 6,412,904 6,398,343 6,652,0746,682,174 6,648,453 6,682,176 6,755,509 7,222,943 7,188,419 7,168,1667,086,719 11/763,440 11/246,687 11/829,957 11/829,962 11/829,96611/829,967 7,156,508 11/246,684 7,246,886 7,128,400 7,108,355 6,991,3227,287,836 7,118,197 10/728,784 10/728,783 7,077,493 6,962,402 10/728,8037,147,308 7,118,198 7,168,790 7,172,270 7,229,155 6,830,318 7,195,3427,175,261 10/773,183 7,108,356 7,118,202 10/773,186 7,134,744 7,134,7437,182,439 7,210,768 10/773,187 7,134,745 7,156,484 7,118,201 7,111,92610/773,184 11/060,751 11/060,805 11/744,885 11/097,308 11/210,68711/097,212 7,147,306 11/482,953 11/482,977 11/544,778 11/764,8087,156,289 7,178,718 7,225,979 11/084,796 09/575,197 09/722,174 7,175,0797,162,259 11/520,170 11/830,848 11/830,849 7,068,382 10/743,6717,094,910 7,091,344 7,122,685 7,038,066 7,099,019 7,062,651 6,644,6427,064,851 6,965,439 7,093,991 7,190,491 10/932,044 10/965,733 10/965,93310/982,974 7,180,609 11/653,219 6,982,798 6,870,966 6,792,165 7,015,9017,289,882 10/919,379 11/193,481 11/255,941 11/495,814 11/495,8227,055,739 7,182,247 7,082,562 6,766,944 10/409,864 7,108,192 7,111,79110/683,171 6,957,768 6,786,397 11/856,061 11/672,522 11/672,95011/672,947 11/672,891 11/672,954 11/754,310 11/754,321 11/754,32011/754,319 11/754,318 11/754,315 11/754,317 11/754,317 11/754,31411/754,313 11/754,312 11/754,311 7,132,679 6,755,513 6,904,678 7,097,2736,824,245 7,222,947 6,860,581 6,929,351 7,063,404 11/066,161 11/066,1606,804,030 10/727,181 10/754,536 10/754,938 10/934,720 6,795,21511/482,981 7,195,328 10/854,521 10/934,628 11/601,757 11/014,731 D529081D528597 6,924,907 10/636,234 10/636,233 7,301,567 10/636,216 7,274,4857,139,084 7,173,735 7,068,394 7,286,182 7,086,644 7,250,977 7,146,2817,023,567 7,134,683 7,083,254 6,796,651 7,061,643 7,057,758 6,894,8106,995,871 7,085,010 7,092,126 7,123,382 7,061,650 10/853,143 11/225,15811/544,764 11/293,804 11/293,794 11/293,828 11/482,978 11/640,35611/679,786 10/760,254 11/014,764 11/014,763 11/014,748 11/014,74711/014,761 11/014,760 11/014,757 11/014,714 7,249,822 11/014,76211/014,724 11/014,723 11/014,756 11/014,736 11/014,759 11/014,75811/014,725 11/014,739 11/014,738 11/014,737 11/014,726 11/014,74511/014,712 7,270,405 11/014,751 11/014,735 11/014,734 11/014,71911/014,750 11/014,749 7,249,833 11/014,769 11/014,729 11/014,74311/014,733 11/014,754 11/014,755 11/014,765 11/014,766 11/014,7407,284,816 7,284,845 7,255,430 11/014,744 11/014,741 11/014,76811/014,767 11/014,718 11/014,717 11/014,716 11/014,732 11/014,74211/097,268 11/097,185 11/097,184 11/293,820 11/688,863 11/688,86411/688,865 11/688,866 11/741,766 11/482,982 11/495,819 11/677,04911/014,722 D528156 10/760,180 6,340,451 7,093,494 6,454,482 11/014,72811/014,727 D536031 7,237,888 10/760,214 10/962,413 10/962,427 7,261,4777,225,739 10/962,402 10/962,425 10/962,428 7,191,978 10/962,42610/962,409 10/962,417 10/962,403 7,163,287 7,258,415 10/962,5237,258,424 10/962,410 11/223,262 10/853,270 6,485,123 6,378,990 6,425,6586,488,346 6,814,429 6,471,336 6,457,813 6,540,331 6,454,396 6,464,3256,443,559 6,435,664 6,412,914 6,488,360 6,550,896 6,439,695 6,447,10009/900,160 6,488,344 7,044,589 6,416,154 6,547,340 6,644,771 6,565,1816,857,719 6,702,417 6,918,654 6,652,078 6,623,108 6,625,874 6,921,1536,536,874 6,425,651 6,435,667 6,527,374 6,582,059 6,513,908 6,540,3326,547,368 6,679,584 6,857,724 6,652,052 6,672,706 6,588,886 7,207,6546,934,224 6,927,786 6,916,082 6,978,990 7,285,170 7,066,580 6,984,0237,059,706 7,185,971 7,090,335 6,739,701 7,008,503 10/636,274 6,792,7546,860,107 6,786,043 6,866,369 6,886,918 6,827,427 6,918,542 7,007,8526,988,840 6,984,080 6,863,365 7,524,016 12/014,772 11/246,687 12/062,51412/062,517 12/062,518 7,819,515 7,891,794 12/062,522 7,891,78812/062,524 7,878,635 12/062,526 7,874,662 12/062,528 7,878,639 7,891,7957,878,640 12/192,116 7,883,189 12/192,118 12/192,119 7,887,148 7,887,170

BACKGROUND OF INVENTION

Most inkjet printers have a scanning or reciprocating printhead that isrepeatedly scanned or reciprocated across the printing width as themedia incrementally advances along the media feed path. This allows acompact and low cost printer arrangement. However, scanning printheadbased printing systems are mechanically complex and slow in light ofaccurate control of the scanning motion and time delays from theincremental stopping and starting of the media with each scan.

Media width printheads resolve this issue by providing a stationaryprinthead spanning the media. Such media width printers offer highperformance but larger printheads require a higher ink supply flow rateand the pressure drop in the ink from the ink inlet on the printhead tonozzles remote from the inlet can change the drop ejectioncharacteristics. Large supply flow rates necessitate large ink tankswhich exhibit a large pressure drop when the ink level in low comparedto the hydrostatic pressure generated when the ink tank is full.Individual pressure regulators integrated into each printhead isunwieldy and expensive for multi-color printheads, particularly thosecarrying four or more inks. For example, a system with five inks wouldrequire 25 regulators.

Inkjet printers that can prime, deprime and purge air bubbles from theprinthead offer the user distinct advantages. Removing a depletedprinthead can cause inadvertent spillage of residual ink if it has notbeen de-primed before decoupling from the printer.

Air bubbles trapped in printheads are a perennial problem and a commoncause of print artifacts. Actively and rapidly removing air bubbles fromthe printhead allows the user to rectify print problems withoutreplacing the printhead. Active priming, de-priming and air purgingtypically use a lot of ink, particularly if the ink is drawn through thenozzles by vacuum or the like. This is exacerbated by large arrays ofnozzles as more ink is lost as the number of nozzles increases.

Thus, there is a need to have a fluid distribution solution that issimpler, more reliable and more effective for media wide printingsystems.

Further, such media width printheads having a large array of inkjetnozzles are difficult to maintain. For example, there is a need tomaintain the printheads which becomes exceptionally difficult when thearray of nozzles is as long as the media is wide. Further, themaintenance stations typically need to be located offset from theprintheads so as not to interfere with media transport.

Some previous systems move the printheads to the servicing stations whennot printing. However, when a printhead is returned to its operativeposition its alignment for correct printing is prone to drift untileventually visible artifacts demand hardware and/or software mechanismsto realign the printhead. In other previous systems, the servicestations translate from their offset position to service the printheadswhile the printheads are raised sufficiently above the media path. Bothof these system designs suffer from drawbacks of large printer widthdimensions, complicated design and control, and difficulty inmaintaining printhead alignment. Further, these systems add size to theprinter. Thus, there is a need to have a media wide printheadmaintenance solution that is simpler, more compact and more effectivefor media wide printing systems.

Further, the high media transport speeds used in such media widthprinters, particularly those which print on continuous web media, havetypically lead to more complex media transport systems in the printers,due to the need to minimize media feed errors. Thus, there is a need tohave a media transport solution that is simpler and more reliable formedia wide printing systems.

SUMMARY OF INVENTION

In one aspect the present invention provides a system for distributingfluid and gas within a printer, comprising:

a fluid container having three fluid ports;

a first fluid path connecting the first fluid port to a printhead of theprinter;

a second fluid path connecting the second fluid port to the printhead;and

a third fluid path connecting the third fluid port to a gas vent,

wherein the first and second fluid ports are configured so that fluidfrom the fluid container flows between the first and second fluid pathsvia the printhead and the third fluid port is configured so that gasflows between the fluid container and gas vent.

Optionally, the system further comprises a valve connecting the firstpath to the printhead.

Optionally, the first and second paths, printhead and fluid containerform a closed fluid flow loop in which fluid flows to and from the fluidcontainer in either direction of the loop.

Optionally, the system further comprises a bi-directional pump on thefirst or second paths for driving said fluid flows to and from the fluidcontainer in either direction of the loop.

Optionally, each of the first, second and third fluid ports of the fluidcontainer incorporate a septum into which a septum needle of tubing ofthe corresponding first, second and third fluid paths is sealinglyinserted.

Optionally, each septum comprises a first septum having a membrane whichis piercable by the septum needle and a slit septum having a slitthrough which the septum needle passes.

In another aspect, the present invention provides a fluid container fora printing system, the fluid container comprising:

a body defining a fluid reservoir;

a first fluid port for connecting the fluid reservoir to a first fluidpath of a printhead of the printing system;

a second fluid port for connecting the fluid reservoir to a second fluidpath of the printhead; and

a third fluid port for connecting the fluid reservoir to a third fluidpath to a gas vent.

Optionally, each of the first, second and third fluid ports incorporatea septum into which a septum needle of tubing of the correspondingfirst, second and third fluid paths is sealingly inserted.

Optionally, each septum comprises a first septum having a membrane whichis piercable by the septum needle and a slit septum having a slitthrough which the septum needle passes.

Optionally, the first and second septa are adjacently disposed withineach of the first, second and third fluid ports so that the septumneedle passes through the slit of the second septum before piercing thefirst septum.

Optionally, the first and second septa are formed of resilient material.

Optionally, the resilient material of the first septum is compatiblewith the fluid contained in the fluid reservoir.

Optionally, the resilient material of the first septum is low elongationnitrile rubber and the fluid contained in the fluid reservoir is ink.

Optionally, the resilient material of the second septum is notcompatible with the fluid contained in the fluid reservoir.

Optionally, the resilient material of the second septum is isoprene andthe fluid contained in the fluid reservoir is ink.

In another aspect the present invention provides a septum assembly for afluid container, the assembly comprising:

a first septum having a membrane which is piercable by a septum needlesealingly located within a fluid port of the fluid container whichcommunicates with a fluid reservoir of the fluid container; and

a second septum having a slit through which the septum needle passessealingly located within the fluid port of the fluid container adjacentthe first septum so that the septum needle passes through the slit ofthe second septum before piercing the first septum.

Optionally, the first and second septa are formed of resilient material.

Optionally, the resilient material of the first septum is compatiblewith the fluid contained in the fluid reservoir.

Optionally, the resilient material of the first septum is low elongationnitrile rubber and the fluid contained in the fluid reservoir is ink.

Optionally, the resilient material of the second septum is notcompatible with the fluid contained in the fluid reservoir.

Optionally, the resilient material of the second septum is isoprene andthe fluid contained in the fluid reservoir is ink.

Optionally, the first septum is circular in form with an annular sealformed at the circumferential edge which is configured to be pressed anddeformed against the inner wall of the fluid port.

Optionally, the first septum has a frustoconical surface connecting theannular seal to a central portion of the first septum.

Optionally, the central portion is formed as a thin membrane which ispierceable by the septum needle.

Optionally, the thin membrane has radial score lines.

Optionally, the thin membrane has stress concentration geometry formedas a groove concentric with a central point of the membrane.

Optionally, the second septum is circular in form with two annular sealsformed at the circumferential edge which are configured to be pressedand deformed against the inner wall of the fluid port.

Optionally, the first septum has an annular detent between the annularseals which connects the annular seals to a central portion of thesecond septum.

Optionally, the central portion has a slit through which the septumneedle is able to sealingly pass.

In another aspect the present invention provides a system for reducingink color mixing effects in a printer, the system comprising:

a printhead having multiple ink color channels mounted to a housing ofthe printer at a first level; and

a plurality of ink supply cartridges mounted to the printer housing soas to be fluidically connected to the printhead and stacked in an arrayhaving a plurality of rows defining a plurality of levels which arelower than the first level,

wherein the plurality of ink supply cartridges include at least oneblack ink supply cartridge which supplies black colored ink to a blackink color channel of the printhead, the black ink supply cartridge beingdisposed at the lowest level defined by the array.

Optionally, the plurality of ink supply cartridges include two black inksupply cartridges which supplies black colored ink to the black inkcolor channel of the printhead, a cyan ink supply cartridge whichsupplies cyan colored ink to a cyan ink color channel of the printhead,a magenta ink supply cartridge which supplies magenta colored ink to amagenta ink color channel of the printhead and a yellow ink supplycartridge which supplies yellow colored ink to a yellow ink colorchannel of the printhead.

Optionally, the array has three rows and three columns, the black inksupply cartridges being disposed at the lowest row in the first andthird columns of the array, the magenta and cyan ink supply cartridgesbeing disposed at the middle row in the first and third columns of thearray and the yellow ink supply cartridge being disposed at the highestrow in the second column of the array.

In another aspect the present invention provides a system for ventinggas at ink containers which supply inks to a multi-channel inkjetprinthead, the system comprising:

a plurality of ink containers for supplying fluids to a printhead havinga plurality of ink channels, each ink container having an ink portconnected to a corresponding one of the ink channels of the printheadand a gas port;

a gas vent assembly having a plurality of gas vents, each gas vent beingconnected to a corresponding one of the gas ports of the ink containers,

wherein the gas vents of the gas vent assembly are in fluidcommunication with the external atmosphere.

Optionally, each gas vent comprises a tortuous path from an interior ofthat gas vent to the external atmosphere.

Optionally, the tortuous path is a serpentine path.

Optionally, the gas vent assembly comprises a body having an interiorsurface which defines a plurality of discrete chambers on one side ofthe body and a plurality of compartments on the opposite side of thebody, the chambers and compartments being sealed within the body.

Optionally, the interior surface in each chamber has a recess in whichapertures connect the chambers with one of the compartments through theinterior surface.

Optionally, the recess of each chamber sealingly seats a filter.

Optionally, the filters comprise hydrophobic material.

Optionally, the hydrophobic material is expandedpolytetrafluoroethylene.

Optionally, each chamber has a transfer port connected to the gas portof a corresponding one of the ink containers.

Optionally, each chamber is connected to a series of the compartmentsvia the corresponding aperture in the interior surface.

Optionally, each compartment of each series of the compartments islinked by a tortuous path to an adjacent compartment of that series.

Optionally, the ultimate compartment of each series of the compartmentswhich is furthest from the connecting aperture is fluidically open tothe external atmosphere via a tortuous path.

Optionally, the each chamber has an overflow port connected to overflowtubing through which ink in that chamber can overflow.

Optionally, the each overflow port has a check valve so that back flowof ink from the connected overflow tubing is prevented.

Optionally, the check valves are elastomeric duckbill check valves.

In another aspect the present invention provides a multi-channel gasvent apparatus for venting gas at ink containers which supply inks to amulti-channel printhead, the apparatus comprising:

a body having a plurality of sidewalls and an interior surface;

a plurality of discrete chambers defined on one side of the interiorsurface by internal sidewalls and being sealed within the body, eachchamber for connection to a gas port of a corresponding one of aplurality of ink containers, each ink container having an ink portconnected to a corresponding one of the ink channels of the printhead;and

a plurality of compartments defined on the opposite side of the interiorsurface by internal sidewalls and being sealed within the body, eachcompartment being in fluid communication with the external atmosphere,

wherein the interior surface in each chamber has a recess in whichapertures connect the chambers with one of the compartments through theinterior surface.

Optionally, the recess of each chamber sealingly seats a filter.

Optionally, the filters comprise hydrophobic material.

Optionally, the hydrophobic material is expandedpolytetrafluoroethylene.

Optionally, each chamber has a transfer port connected to the gas portof a corresponding one of the ink containers.

Optionally, each chamber is connected to a series of the compartmentsvia the corresponding aperture in the interior surface.

Optionally, each compartment of each series of the compartments islinked by a tortuous path to an adjacent compartment of that series.

Optionally, the ultimate compartment of each series of the compartmentswhich is furthest from the connecting aperture is fluidically open tothe external atmosphere via a tortuous path.

Optionally, the each chamber has an overflow port connected to overflowtubing through which ink in that chamber can overflow.

Optionally, the each overflow port has a check valve so that back flowof ink from the connected overflow tubing is prevented.

Optionally, the check valves are elastomeric duckbill check valves.

In another aspect the present invention provides a printing systemcomprising:

a media width printhead;

a plurality of ink containers fluidically interconnected with theprinthead via a respective plurality of ink tubes;

a plurality of gas vents fluidically interconnected with the printheadvia a respective plurality of gas tubes;

a multi-channel valve arrangement for selectively moving a first pinchelement into and out of pinching contact with the ink tubes so as torespectively block and allow fluid flow through the ink tubes andselectively moving a second pinch element into and out of pinchingcontact with the gas tubes so as to respectively block and allow fluidflow through the gas tubes.

Optionally, the multi-channel valve arrangement comprises:

a body;

a plurality of ink ports defined through the body, each ink port beingconfigured to receive a respective one of the ink tubes therethrough;

a plurality of gas ports defined through the body, each gas port beingconfigured to receive a respective one of the gas tubes therethrough;and

a pinch drive arrangement for selectively moving the first and secondpinch elements.

Optionally, the pinch drive arrangement comprises a shaft rotatablymounted to the body, eccentric cams fixedly mounted on the shaft, andsprings interconnecting the first and second pinch elements to the shaftso that the eccentric cams contact the first and second pinch elements.

Optionally, each spring is formed as a bent spring having one springportion connected to the first pinch element, a second spring portionconnected to the second pinch element, and a central portion mountedabout one end of the shaft.

Optionally, the first and second spring portions of each spring areconfigured to bias the first and second pinch elements toward the shaft,respectively.

Optionally, the springs are compression springs.

Optionally, the eccentric cams are configured so that rotation of theshaft causes said selective movement of the first and second pinchelements with or against the bias of the springs.

Optionally, the multi-channel valve arrangement further comprises aplurality of plurality of check valves, each check valve being locatedon a respective one of the gas tubes.

Optionally, the check valves are elastomeric duckbill check valves.

Optionally, each gas vent comprises a filter disposed at one end of thecorresponding gas tube, the opposite end of the gas tube being connectedto the printhead.

Optionally, the filters comprise expanded polytetrafluoroethylene

In another aspect the present invention provides a multi-channel valveapparatus for a multi-channel printhead, the apparatus comprising

a plurality of ink ports defined through the body, each ink port beingconfigured to receive therethrough a respective one of a plurality ofink tubes interconnecting a plurality of ink containers with theprinthead;

a plurality of gas ports defined through the body, each gas port beingconfigured to receive therethrough a respective one of a plurality ofgas tubes interconnecting a plurality of gas vents with the printhead;

a first pinch element arranged to be moved into and out of pinchingcontact with the ink tubes so as to respectively block and allow fluidflow through the ink tubes;

a second pinch element arranged to be moved into and out of pinchingcontact with the gas tubes so as to respectively block and allow fluidflow through the gas tubes; and

a pinch drive arrangement for selectively moving the first and secondpinch elements.

Optionally, the pinch drive arrangement comprises a shaft rotatablymounted to the body, eccentric cams fixedly mounted on the shaft, andsprings interconnecting the first and second pinch elements to the shaftso that the eccentric cams contact the first and second pinch elements.

Optionally, each spring is formed as a bent spring having one springportion connected to the first pinch element, a second spring portionconnected to the second pinch element, and a central portion mountedabout one end of the shaft.

Optionally, the first and second spring portions of each spring areconfigured to bias the first and second pinch elements toward the shaft,respectively.

Optionally, the springs are compression springs.

Optionally, the eccentric cams are configured so that rotation of theshaft causes said selective movement of the first and second pinchelements with or against the bias of the springs.

Optionally, the multi-channel valve arrangement further comprises aplurality of plurality of check valves, each check valve being locatedon a respective one of the gas tubes.

Optionally, the check valves are elastomeric duckbill check valves.

Optionally, each gas vent comprises a filter disposed at one end of thecorresponding gas tube, the opposite end of the gas tube being connectedto the printhead.

Optionally, the filters comprise expanded polytetrafluoroethylene.

In another aspect the present invention provides a maintenance systemfor a printhead, the system comprising:

a support frame;

a wiper module supported by the support frame, the wiper modulecomprising a wiper roller on a rotatable shaft and a porous materialabout the shaft, and a transfer roller in rotatable contact with thewiper roller;

a lift mechanism for lifting the wiper module from the support frame toposition the porous material of the wiper roller against the printhead;and

a rotation mechanism for rotating the wiper and transfer rollers so thatthe porous material of the wiper roller rotates against the printhead,the porous material being configured to absorb fluid from the printheadduring said rotation, and so that the fluid absorbed by the porousmaterial of the wiper roller is transferred to the transfer roller.

Optionally, the wiper module further comprises a compressible coremounted to the shaft, the porous material being provided over the core;and

the lift mechanism is configured to position the porous material againstthe printhead so as to compress the compressible core.

Optionally, the core is formed of extruded closed-cell foam.

Optionally, the transfer roller comprises a smooth hard cylinder whichcontacts the wiper roller so as to compress the compressible core.

Optionally, the porous material is formed of non-woven microfiber.

Optionally, the non-woven microfiber is wrapped about the core by aspiralling technique so that at least two layers of the microfiber arepresent about the core with an adhesive between the layers.

In another aspect the present invention provides an apparatus formaintaining a printhead, the apparatus comprising:

a rotatable wiper roller comprising a shaft and a porous material aboutthe shaft;

a rotatable transfer roller in rotatable contact with the wiper roller;and

a mechanism for rotating the wiper roller so that the porous materialrotates against the printhead, the porous material being configured toabsorb fluid from the printhead during said rotation, and for rotatingthe transfer roller against the wiper roller so that the fluid absorbedby the porous material is transferred to the transfer roller.

Optionally, the printhead is a media width printhead, and the wiper andtransfer rollers are elongate with a longitudinal length of at least themedia width.

Optionally, the wiper and transfer rollers are rotatably mounted to awiper module supported by a sled.

Optionally, the transfer roller is mounted to the wiper module so thatthe transfer roller contacts the wiper roller on a verticalcircumferential region of the wiper roller below the uppercircumferential region of the wiper roller which contacts the printhead.

Optionally, the wiper roller comprises a compressible core mounted tothe shaft, the porous material being provided over the core.

Optionally, the porous material is formed of non-woven microfiber.

Optionally, the non-woven microfiber is wrapped about the core by aspiralling technique so that at least two layers of the microfiber arepresent about the core with an adhesive between the layers.

Optionally, the transfer roller comprises a smooth hard cylinder.

Optionally, the smooth hard cylinder is mounted to the wiper module sothat contact pressure is exerted on the compressible core of the wiperroller.

In another aspect the present invention provides a maintenance systemfor a printhead, the system comprising:

a support frame;

a wiper module supported by the support frame, the wiper modulecomprising a porous roller for rotatably contacting the printhead toabsorb fluid and particulates from the printhead, a non-porous roller inrotatable contact with the porous roller to transfer the absorb fluidand particulates from the porous roller, and a scraper in contact withthe non-porous roller to remove the transferred fluid and particulatesfrom the non-porous roller during said rotation;

a lift mechanism for lifting the wiper module from the support frame toposition the porous roller against the printhead; and

a rotation mechanism for rotating the porous and non-porous rollers sothat the porous roller rotates against the printhead and the non-porousroller is rotated against the porous roller and the scraper.

Optionally, the porous roller comprises porous material over acompressible core; and

the lift mechanism is configured to position the porous material againstthe printhead so as to compress the compressible core.

Optionally, the core is formed of extruded closed-cell foam.

Optionally, the non-porous roller comprises a smooth hard cylinder whichcontacts the porous roller so as to compress the compressible core.

Optionally, the porous material is formed of non-woven microfiber.

Optionally, the scraper is resiliently flexible.

In another aspect the present invention provides an apparatus formaintaining a printhead, the apparatus comprising:

a rotatable porous roller;

a rotatable non-porous roller in rotatable contact with the porousroller;

a scraper in contact with the non-porous roller; and

a mechanism for rotating the porous and non-porous rollers so that theporous roller rotates against the printhead and the non-porous roller isrotated against the porous roller and the scraper, the porous rollerbeing configured to absorb fluid and particulates from the printheadduring said rotation, the non-porous roller being configured to transferthe absorbed fluid and particulates from the porous roller, and thescraper being configured to clean the transferred fluid and particulatesfrom the non-porous roller during said rotation.

Optionally, the printhead is a media width printhead, and the porous andnon-porous rollers and scraper are elongate with a longitudinal lengthof at least the media width.

Optionally, the porous and non-porous rollers are rotatably mounted to awiper module supported by a sled.

Optionally, the non-porous roller is mounted to the wiper module so thatthe non-porous roller contacts the porous roller on a verticalcircumferential region of the porous roller below the uppercircumferential region of the porous roller which contacts theprinthead.

Optionally, the porous roller comprises porous material over acompressible core.

Optionally, the porous material is formed of non-woven microfiber.

Optionally, the non-porous roller comprises a smooth hard cylinder.

Optionally, the smooth hard cylinder is mounted to the wiper module sothat contact pressure is exerted on the compressible core of the porousroller.

Optionally, the scraper is mounted to the wiper module so that thescraper contacts the non-porous roller on a vertical circumferentialregion of the non-porous roller below the upper circumferential regionof the non-porous roller which contacts the porous roller.

Optionally, the scraper is resiliently flexible.

In another aspect the present invention provides a wiping device formaintaining a printhead, the wiping device comprising:

a body supported within a maintenance unit of the printer;

a porous roller rotatably mounted to the body, the body being configuredto be lifted from the maintenance unit so as bring the porous rollerinto contact with a printhead of the printer; and

a mechanism mounted to the body for rotating the porous roller so thatthe porous roller rotates against the printhead wiping the printheadclean, the mechanism being connectable to a power supply of the printerand being configured to be lifted from the maintenance unit togetherwith the body whilst connected to the power supply.

Optionally, the printhead is a media width printhead, and the porousroller is elongate with a longitudinal length of at least the mediawidth.

Optionally, the mechanism comprises a motor and a gear train connectedbetween a gear of the motor and a gear of the porous roller, the motorand gear train being mounted within the body.

Optionally, the motor is powered through a flexible connection with thepower supply of the printer.

Optionally, the device further comprises a non-porous roller rotatablymounted to the body in contact with the porous roller,

wherein the mechanism rotates the non-porous roller so that thenon-porous roller rotates against the porous roller cleaning the porousroller.

Optionally, the mechanism comprises a motor and a gear train connectedbetween a gear of the motor and gears of the porous and non-porousrollers, the motor and gear train being mounted within the body.

Optionally, the motor is powered through a flexible connection with thepower supply of the printer.

Optionally, the porous roller comprises porous material over acompressible core.

Optionally, the non-porous roller comprises a smooth hard cylinder.Optionally, the smooth hard cylinder is mounted to the body so thatcontact pressure is exerted on the compressible core of the porousroller.

In another aspect the present invention provides a maintenance systemfor a printhead, the system comprising:

a sled;

a wiper module supported by the sled, the wiper module comprisingrotatable porous and non-porous rollers in contact with one another;

a lift mechanism for lifting the wiper module from the sled to positionthe porous roller against the printhead;

a rotation mechanism for rotating the porous and non-porous rollers sothat the porous roller of the lifted wiper module rotates against theprinthead and the non-porous roller rotates against the porous roller,the porous roller being configured to absorb fluid from the printheadduring said rotation and the non-porous roller being configured to cleanthe absorbed fluid from the porous roller; and

a sliding mechanism for sliding the sled relative to the printhead sothat the rotating porous roller is wiped across the printhead.

Optionally, the rotation mechanism is mounted to the wiper module and isconnectable to a power supply of the printhead such that the rotationmechanism is lifted from the sled together with the wiper module whilstconnected to the power supply.

Optionally, the mechanism comprises a motor and a gear train connectedbetween a gear of the motor and gears of the porous and non-porousrollers, the motor and gear train being mounted on the wiper module.

Optionally, the motor is powered through a flexible connection with thepower supply of the printhead.

Optionally, the sliding mechanism comprises a rack on each end of thesled corresponding to each end of the wiper module, and a pinion gear oneach end of a shaft so as to each couple with a corresponding one of theracks and a motor.

Optionally, the porous roller comprises porous material over acompressible core; and

the lift mechanism is configured to position the porous material againstthe printhead so as to compress the compressible core.

Optionally, the non-porous roller comprises a smooth hard cylinder.

Optionally, the smooth hard cylinder is mounted to the wiper module sothat contact pressure is exerted on the compressible core of the porousroller.

In another aspect the present invention provides a system fortransporting media in a printer, the system comprising:

a housing of the printer;

at least one roller rotatably mounted to the housing for transportingmedia through the printer;

a motor mounted to the housing;

a drive belt looped about a drive shaft of the motor and the roller soas to impart rotational driving force of the motor to the roller;

a tensioning member pivotally mounted to the housing for contacting andthereby tensioning the drive belt about the motor drive shaft androller, the pivoted position of the tensioning member relative to thehousing determining the amount of tension imparted on the drive belt;

a brace member mounted to the housing about a slotted arm of thetensioning member; and

a locking screw fixed to the housing through the brace member andslotted arm to lock the pivoted position of the tensioning member, thebrace member being fixedly mounted to the housing so that rotation ofthe locking screw is not imparted to the slotted arm during fixing ofthe locking screw to the housing.

Optionally, the system further comprises a spring for biasing a bushingof the tensioning member against the drive belt thereby imparting thetension on the drive belt.

Optionally, the brace member is elongate and has pins at either endwhich are snugly received within respective holes of the housing suchthat the brace member is unable to rotate relative to the housing.

Optionally, the slotted arm has a curved slot through which a screw holeof the housing is exposed through plural pivoted positions of thetensioning member.

Optionally, the brace member has a hole which is aligned with theexposed screw hole in the housing.

Optionally, the locking screw is fixed within the exposed screw hole viathe hole in the brace member.

Optionally, the system comprises a plurality of rollers rotatablymounted to the housing for transporting media through the printer,

wherein the drive belt is looped about each of the rollers so as toimpart rotational driving force of the motor to the rollers.

In another aspect the present invention provides a drive belt tensioningapparatus for a printer, the apparatus comprising:

a tensioning member pivotally mounted to a housing of the printer so asto contact and thereby tension a drive belt about a drive shaft of amotor and at least one roller so as to impart rotational driving forceof the motor to the roller for transporting media through the printer,the pivoted position of the tensioning member relative to the housingdetermining the amount of tension imparted on the drive belt;

a brace member mounted to the housing about a slotted arm of thetensioning member; and

a locking screw fixed to the housing through the brace member andslotted arm to lock the pivoted position of the tensioning member, thebrace member being fixedly mounted to the housing so that rotation ofthe locking screw is not imparted to the slotted arm during fixing ofthe locking screw to the housing

Optionally, the apparatus further comprises a spring for biasing abushing of the tensioning member against the drive belt therebyimparting the tension on the drive belt.

Optionally, the brace member is elongate and has pins at either endwhich are snugly received within respective holes of the housing suchthat the brace member is unable to rotate relative to the housing.

Optionally, the slotted arm has a curved slot through which a screw holeof the housing is exposed through plural pivoted positions of thetensioning member.

Optionally, the brace member has a hole which is aligned with theexposed screw hole in the housing.

Optionally, the locking screw is fixed within the exposed screw hole viathe hole in the brace member.

In another aspect the present invention provides a system for aligningdriven and idler rollers in a printer, the system comprising:

a housing of the printer, the housing having a first housing portionhingedly mounted to a second housing portion such that the secondhousing portion is movable with respect to the first housing portionbetween open and closed positions;

at least one driven roller rotatably mounted to the first housingportion for transporting media through the printer;

at least one idler roller rotatably supported within the second housingportion for contact with the driven roller so as to provide pinchedcontact on the transported media; and

an alignment adjustment mechanism for aligning the idler roller with thedriven roller as the second housing portion is hinged into the closedposition with the first housing portion.

Optionally, the driven roller is rotatably mounted to the first housingportion by bearing members which are fixedly mounted to the firsthousing portion.

Optionally, the idler roller is rotatably supported

by a pinch housing constrained within the pinch roller assembly mountedto the second housing portion, the pinch housing being movable withrespect to the second housing portion.

Optionally, the alignment adjustment mechanism comprises slots definedin the bearing members and alignment pins defined on the pinch housing,the alignment pins being configured to engage with the slots as thesecond housing portion is hinged to the closed position with the firsthousing portion, said engagement causing said movement of the pinchhousing relative to the second housing portion thereby aligning theidler and driven rollers.

Optionally, the slots of the bearing members have sloped outer surfaceswhich funnel the alignment pins into the slots as the second housingportion is hinged to the closed position with the first housing portion.

In another aspect the present invention provides a pinch rollerapparatus for a printer, the apparatus comprising:

a support plate securely mounted to a housing of the printer;

a pinch housing movably supported by the support plate; and

a series of pinch rollers rotatably held within the pinch housing,

wherein the pinch housing has alignment pins for engagement with thehousing of the printer through said movement of the pinch housingrelative to the support plate, said engagement aligning the pinchrollers with a driven roller rotatably mounted to the housing to providepinched contact for media being transported through the printer.

Optionally, the printhead is a media width printhead, and the supportplate and pinch housing are elongate with a longitudinal length of atleast the media width such that the series of pinch rollers extendsalong the media width.

Optionally, the pinch housing is linked to the support plate by springsat either longitudinal end of the pinch housing and support plate.

Optionally, the apparatus further comprises a mounting plate securelymounted to the housing of the printer, the support plate being securelymounted to the mounting plate, the mounting plate having tabs on whichthe pinch housing is held.

Optionally, the housing of the printer has a first housing portionhingedly mounted to a second housing portion, the support plate beingsecurely mounted to the second housing portion and the driven rollerbeing rotatably mounted to the first housing portion.

Optionally, the alignment pins of the pinch housing engage with thehousing of the printer as the second housing portion is hinged into aclosed position with the first housing portion.

Optionally, the driven roller is rotatably mounted to the first housingportion by bearing members which are fixedly mounted to the firsthousing portion, the alignment pins being configured to engage withslots in the bearing members as the second housing portion is hinged tothe closed position with the first housing portion, said engagementcausing said movement of the pinch housing relative to the secondhousing portion thereby aligning the pinch and driven rollers.

Optionally, an axle of each pinch roller is rotatably held within acorresponding slot of the pinch housing by a respective lever member,the lever members being pivotally supported by the support plate andmovably supported by the pinch housing.

Optionally, the apparatus further comprises springs between the levermembers and the mounting plate, the springs being configured so that thelever members are biased away from the mounting plate thereby urging thepinch rollers toward the driven roller.

In another aspect the present invention provides a pinch roller assemblyfor a printer having a media width printhead, the assembly comprising:

an elongate support plate securely mounted to a housing of the printerso as to extend along the media width;

two elongate pinch housings movably supported on either side the supportplate so as to extend along the media width; and

a series of pinch rollers rotatably held within each pinch housing so asto extend along the media width,

wherein the pinch housings have alignment pins for engagement with thehousing of the printer through said movement of the pinch housingsrelative to the support plate, said engagement aligning the series ofpinch rollers with a respective driven roller rotatably mounted to thehousing to provide pinched contact for media being transported throughthe printer.

Optionally, the pinch housings are linked to the support plate bysprings at either longitudinal end of the pinch housings and supportplate.

Optionally, the assembly further comprises a mounting plate securelymounted to the housing of the printer, the support plate being securelymounted to the mounting plate, the mounting plate having tabs on whichthe pinch housings are held.

Optionally, the housing of the printer has a first housing portionhingedly mounted to a second housing portion, the support plate beingsecurely mounted to the second housing portion and the driven rollersbeing rotatably mounted to the first housing portion.

Optionally, the alignment pins of the pinch housings engage with thehousing of the printer as the second housing portion is hinged into aclosed position with the first housing portion.

Optionally, the driven rollers are rotatably mounted to the firsthousing portion by bearing members which are fixedly mounted to thefirst housing portion, the alignment pins being configured to engagewith slots in the bearing members as the second housing portion ishinged to the closed position with the first housing portion, saidengagement causing said movement of the pinch housings relative to thesecond housing portion thereby aligning the pinch and driven rollers.

Optionally, an axle of each pinch roller is rotatably held within acorresponding slot of the corresponding pinch housing by a respectivelever member, the lever members being pivotally supported by the supportplate and movably supported by the pinch housings.

Optionally, the assembly further comprises springs between the levermembers and the mounting plate, the springs being configured so that thelever members are biased away from the mounting plate thereby urging thepinch rollers toward the driven rollers.

BRIEF DESCRIPTION OF DRAWINGS

The exemplary features, best mode and advantages of the invention willbe understood by the description herein with reference to accompanyingdrawings, in which:

FIG. 1 is a block diagram of the main system components of a printer;

FIG. 2 is a perspective view of a printhead of the printer;

FIG. 3 illustrates the printhead with a cover removed;

FIG. 4 is an exploded view of the printhead;

FIG. 5 is an exploded view of the printhead without inlet or outletcouplings;

FIG. 6 illustrates an exemplary embodiment of the printer with mostcomponents other than those of fluid distribution, maintenance and mediahandling systems for the printer omitted;

FIG. 7 illustrates an opposite view of the printer as illustrated inFIG. 6;

FIG. 8 schematically illustrates an exemplary embodiment of the fluiddistribution system;

FIG. 9 illustrates a fluid supply cartridge of the fluid distributionsystem;

FIG. 10 is an exploded view of the fluid supply cartridge;

FIG. 11 is a cross-sectional view of the fluid supply cartridge takenthrough line A-A of FIG. 9;

FIG. 12 illustrates a lid of the fluid supply cartridge;

FIG. 13A is a cross-sectional view of the lid taken through line B-B ofFIG. 12;

FIG. 13B illustrates the lid of FIG. 13A with a filter omitted;

FIG. 14 is a cross-sectional view of the lid taken through line C-C ofFIG. 12;

FIG. 15 is a cross-sectional view of the lid taken through line D-D ofFIG. 12;

FIG. 16 illustrates a portion of the cross-sectional view of FIG. 13Ashowing a septum needle for a fluid port of the fluid supply cartridge;

FIGS. 17A and 17B illustrate different views of one exemplary embodimentof a piercable septum of the fluid port;

FIGS. 17C and 17D illustrate different views of another exemplaryembodiment of a piercable septum of the fluid port;

FIGS. 18A and 18B illustrate different views of a slit septum of thefluid port;

FIG. 19 illustrates a layout of the supply cartridges as mounted in theprinter;

FIGS. 20 and 21 illustrate different views of a multi-channel gas ventassembly of the fluid distribution system;

FIG. 22A schematically illustrates another embodiment of the fluiddistribution system incorporating an alternative multi-channel gas ventassembly;

FIG. 22B illustrates the alternative multi-channel gas vent assemblywith waste fluid lines omitted;

FIG. 22C illustrates a different view of the alternative multi-channelgas vent assembly with the waste fluid lines shown;

FIG. 22D schematically illustrates another embodiment of the fluiddistribution system incorporating buffer units;

FIGS. 22F-22H illustrate different views of a single buffer unit;

FIGS. 23A and 23B illustrate different isometric views of amulti-channel valve arrangement of the fluid distribution system;

FIG. 24 is an exploded view of the multi-channel valve arrangement;

FIG. 25 illustrates the multi-channel valve arrangement with a housingand some fluid lines omitted;

FIG. 26 illustrates a cam shaft of the multi-channel valve arrangementin isolation;

FIGS. 27A-27C illustrate different valve states of the multi-channelvalve arrangement;

FIG. 28 schematically illustrates another embodiment of the fluiddistribution system incorporating an on demand de-prime arrangement;

FIG. 29 illustrates a modular maintenance sled of an exemplaryembodiment of the maintenance system;

FIG. 30 is an exploded view of the maintenance sled;

FIG. 31 illustrates a wiper module of an exemplary embodiment of thesled;

FIG. 32 is an exploded view of the wiper module;

FIG. 33 is a cross-sectional view of the sled illustrating the wipermodule position;

FIG. 34 is a bottom isometric view of the sled;

FIG. 35 illustrates a translation mechanism of the sled;

FIG. 36A is a cross-sectional view of the printer with most componentsomitted and illustrating the wiper module engaged with a lift mechanismin a non-lifted position;

FIG. 36B illustrates the wiper module engaged with the lift mechanism ina lifted position;

FIG. 36C illustrates the wiper module in an operational positionrelative to the printhead;

FIG. 37 is a close up view of one section of the lift mechanism;

FIGS. 38A-38G illustrate different schematic views of exemplarytranslated wiping movements of the wiper module;

FIG. 39 illustrates a fluid collection tray of the maintenance system;

FIG. 40 illustrates upper and lower sections of an exemplary embodimentof the media handling system;

FIG. 41 illustrates media guide and drive assemblies of the lowersection of the media handling system;

FIG. 42 illustrates engagement of drive and pinch elements of the driveand pinch assemblies;

FIG. 43 is a perspective view of the pinch assembly with a plate of oneof the pinch elements omitted;

FIG. 44 illustrates one of the pinch elements in isolation;

FIG. 45A illustrates an alignment mechanism of the drive assembly and apinch assembly of the upper section of the media handling system; and

FIG. 45B is a cross-sectional view of the alignment mechanismillustrated in FIG. 45A.

One of ordinary skill in the art will appreciate that the invention isnot limited in its application to the details of construction, thearrangements of components, and the arrangement of steps set forth inthe following detailed description and/or illustrated in theaccompanying drawings. The invention is capable of other embodiments andof being practiced or being carried out in various ways. Also, it is tobe understood that the phraseology and terminology used herein is forthe purpose of description and should not be regarded as limiting.

DETAILED DESCRIPTION OF EMBODIMENTS

An exemplary block diagram of the main system components of a printer100 is illustrated in FIG. 1. The printer 100 has a printhead 200, fluiddistribution system 300, maintenance system 600, electronics 800 andmedia handling system 900.

The printhead 200 has fluid ejection nozzles for ejecting printingfluid, such as ink, onto passing print media. The fluid distributionsystem 300 distributes ink and other fluids for ejection by the nozzlesof the printhead 200. The maintenance system 600 maintains the printhead200 so that reliable and accurate fluid ejection is provided from theejection nozzles. The media handling system 900 provides transport andguidance of media past the printhead 200 for printing.

The electronics 800 operatively interconnects the electrical componentsof the printer 100 to one another and to external components/systems.The electronics 800 has control electronics 802 for controllingoperation of the connected components. An exemplary configuration of thecontrol electronics 802 is described in US Patent ApplicationPublication No. 20050157040 (Applicant's Docket No. RRC001US), thecontents of which are hereby incorporated by reference.

The printhead 200 may be provided as a media width printhead cartridgeremovable from the printer 100, as described in US Patent ApplicationPublication No. 20090179940 (Applicant's Docket No. RRE017US), thecontents of which are hereby incorporated by reference. This exemplaryprinthead cartridge includes a liquid crystal polymer (LCP) molding 202supporting a series of printhead ICs 204, as illustrated in FIGS. 2-5,which extends the width of media substrate to be printed. When mountedto the printer 100, the printhead 200 therefore constitutes astationary, full media width printhead.

The printhead ICs 204 each comprise ejection nozzles for ejecting dropsof ink and other printing fluids onto the passing media substrate. Thenozzles may be MEMS (micro electro-mechanical) structures printing attrue 1600 dpi resolution (that is, a nozzle pitch of 1600 nozzles perinch), or greater. The fabrication and structure of suitable printheadICs 204 are described in detail in US Patent Application Publication No.20070081032 (Applicant's Docket No. MNN001US), the contents of which arehereby incorporated by reference.

The LCP molding 202 has main channels 206 extending the length of theLCP molding 202 between associated inlet ports 208 and outlet ports 210.Each main channel 206 feeds a series of fine channels (not shown)extending to the other side of the LCP molding 202. The fine channelssupply ink to the printhead ICs 204 through laser ablated holes in thedie attach film via which the printhead ICs are mounted to the LCPmolding, as discussed below.

Above the main channel 206 is a series of non-priming air cavities 214.These cavities 214 are designed to trap a pocket of air during printheadpriming. The air pockets give the system some compliance to absorb anddamp pressure spikes or hydraulic shocks in the printing fluid. Theprinters are high speed pagewidth or media width printers with a largenumber of nozzles firing rapidly. This consumes ink at a fast rate andsuddenly ending a print job, or even just the end of a page, means thata column of ink moving towards (and through) the printhead 200 must bebrought to rest almost instantaneously. Without the compliance providedby the air cavities 214, the momentum of the ink would flood the nozzlesin the printhead ICs 204. Furthermore, the subsequent ‘reflected wave’could otherwise generate sufficient negative pressure to erroneouslydeprime the nozzles.

The printhead cartridge has a top molding 216 and a removable protectivecover 218. The top molding 216 has a central web for structuralstiffness and to provide textured grip surfaces 220 for manipulating theprinthead cartridge during insertion and removal with respect to theprinter 100. Movable caps 222 are provided at a base of the cover andare movable to cover an inlet printhead coupling 224 and an outletprinthead coupling 226 of the printhead 200 prior to installation in theprinter. The terms “inlet” and “outlet” are used to specify the usualdirection of fluid flow through the printhead 200 during printing.However, the printhead 200 is configured so that fluid entry and exitcan be achieved in either direction along the printhead 200.

The base of the cover 218 protects the printhead ICs 204 and electricalcontacts 228 of the printhead prior to installation in the printer andis removable, as illustrated in FIG. 3, to expose the printhead ICs 204and the contacts 228 for installation. The protective cover may bediscarded or fitted to a printhead cartridge being replaced to containleakage from residual ink therein.

The top molding 216 covers an inlet manifold 230 of the inlet coupling224 and an outlet manifold 232 of the outlet coupling 226 together withshrouds 234, as illustrated in FIG. 4. The inlet and outlet manifolds230,232 respectively have inlet and outlet spouts 236,238. Five each ofthe inlet and outlet ports or spouts 236,238 are shown in theillustrated embodiment of the printhead 200, which provide for five inkchannels, e.g., CYMKK or CYMKIR. Other arrangements and numbers of thespouts are possible to provide different printing fluid channelconfigurations. For example, instead of a multi-channel printheadprinting multiple ink colors, several printheads could be provided eachprinting one or more ink colors.

Each inlet spout 236 is fluidically connected to a corresponding one ofthe inlet ports 208 of the LCP molding 202. Each outlet spout 238 isfluidically connected to a corresponding one of the outlet ports 210 ofthe LCP molding 202. Thus, for each ink color, supplied ink isdistributed between one of the inlet spouts 236 and a corresponding oneof the outlet spouts 238 via a corresponding one of the main channels206.

From FIG. 5 it can be seen that the main channels 206 are formed in achannel molding 240 and the associated air cavities 214 are formed in acavity molding 242. Adhered to the channel molding 240 is a die attachfilm 244. The die attach film 244 mounts the printhead ICs 204 to thechannel molding 240 such that the fine channels, which are formed withinthe channel molding 240, are in fluid communication with the printheadICs 204 via small laser ablated holes 245 through the film 244.

The channel and cavity moldings 240,244 are mounted together with acontact molding 246 containing the electrical contacts 228 for theprinthead ICs and a clip molding 248 in order to form the LCP molding202. The clip molding 248 is used to securely clip the LCP molding 202to the top molding 216.

LCP is the preferred material of the molding 202 because of itsstiffness, which retains structural integrity along the media widthlength of the molding, and its coefficient of thermal expansion whichclosely matches that of silicon used in the printhead ICs, which ensuresgood registration between the fine channels of the LCP molding 202 andthe nozzles of the printhead ICs 204 throughout operation of theprinthead 200. However, other materials are possible so long as thesecriteria are met.

The fluid distribution system 300 may be arranged in the printer 100 forthe multiple fluid channels of the printhead 200 as illustrated in FIGS.6 and 7. FIG. 8 schematically illustrates the fluid distribution system300 for a single fluid channel, e.g., for a single colored ink or otherprinting fluid, such as ink fixing agent (fixative). The illustratedembodiment is similar in arrangement and operation as the pinch andcheck valve embodiment of the fluid distribution system described in theApplicant's U.S. Provisional Patent Application No. 61/345,552 (DocketNo. KPF001PUS).

The present embodiment of the fluid distribution system differs from theidentified embodiment of the incorporated description of the Applicant'sU.S. Provisional Patent Application No. 61/345,552 (Docket No.KPF001PUS) in the provision of fluid supply cartridges and a 2-way pinchvalve. These and other components of the present fluid distributionsystem 300 of FIG. 8 are now described in detail. Where suitable, thesame reference numerals for the same components of the incorporateddescription of the Applicant's U.S. Provisional Patent Application No.61/345,552 (Docket No. KPF001PUS) are used. The present embodiment ofthe fluid distribution system provides a simple, passive and gravity fedfluid (ink) distribution system for the printhead.

The fluid distribution system 300 has sealed containers 301 (hereintermed fluid supply cartridges) which contain ink or other fluid/liquidfor supply to the printhead 200 via a closed fluid loop 348. In theillustrated embodiment of FIGS. 6 and 7, five supply cartridges 301 andfive closed fluid loops 348 are provided for the above-discussed fiveink channels of the printhead 200. The fluid supply cartridges of thepresent embodiment are provided in place of the supply and accumulatortanks of the incorporated Applicant's U.S. Provisional PatentApplication No. 61/345,552 (Docket No. KPF001PUS). The manner in whichthe five supply cartridges 301 are mounted to a housing 101 of theprinter 100 is discussed later.

FIGS. 9-12 illustrate one of the supply cartridges 301. As illustrated,the supply cartridge 301 has a body 303 which is sealed with respect toliquids by a lid 305. The body 303 may be molded from two parts 303 aand 303 b which are joined and hermitically sealed by ultrasonic weldingso as to provide an opening 303 c onto which the lid 305 assembled.Alternatively, the body 303 may be molded as a single unit. The body 303has a flange 303 d about the periphery of the opening 303 c which isreceived within a groove 305 a of the lid 305 a, as illustrated in FIG.11. The assembled body 303 and lid 305 are joined and hermiticallysealed by ultrasonic welding so as to form a sealed fluid reservoir.

The body 303 (and the lid 305) is preferably formed of a material whichis inert in ink, has a low water vapor transmission rate (WVTR), can beultrasonically welded and is not susceptible to sympathetic ultrasonicwelding when the lid 305 is ultrasonically welded to the body 303.Suitable materials are polyethylene terephthalate (PET) and acombination of polyphenylene ether and polystyrene, such as Noryl 731.The ultrasonic welding used is preferably a dual shear joint thatcreates a strong hermetic seal and is tolerant to variation in sizebetween the two components. However, other ultrasonic welding or otherjoining and sealing techniques are possible.

One, or both, of the parts 303 a and 303 b of the body 303 is formedwith one or more internal ribs 307. The internal ribs 307 drasticallyimprove the rigidity of the supply cartridge 301. This improved rigidityreduces deformation in the cartridge under conditions of positive ornegative pressurization, such as occurs during shipping and underconditions of shock which can occur during shipping and handling of thecartridge and/or printer. Improved rigidity also may lead to strongerjoints between the cartridge components. A handle 309 is formed as partof the body 303 which provides a grip surface for a user to grasp thesupply cartridge 301 without deforming the cartridge, thereby furtherprotecting the sealed cartridge joints.

The lid 305 of the supply cartridge 301 is illustrated in detail inFIGS. 12-14. As illustrated, the lid 305 has three sealable fluid ports311. The ports 311 serve the following functions: a fluid outlet port313; a gas port 315; and a fluid inlet (or return) port 317. Ink orother printing fluids contained in the supply cartridge 301 can be drawnthrough the outlet 313 into the closed fluid loop 348 and returned viathe closed loop 348 to the supply cartridge 301 through the inlet 317.Whilst the gas port 315 allows gases, such as ambient air and internalvapours, to pass into and out of the supply cartridge 301. Thisarrangement allows the internal gas pressure of the supply cartridge 301to be equalized to external ambient conditions.

Each of the ports 311 has an internal channel 311 a which communicateswith the exterior of the cartridge 301 at an external aperture 311 b andcommunicates with the interior fluid reservoir of the cartridge 301 atan internal aperture 311 c. The internal aperture 311 c of the outlet313 is formed as a channel 313 a which communicates with a filtercompartment 319 formed on the lid 305. As illustrated in FIGS. 13A and13B, the filter compartment 319 has a plate 319 a into which the channel313 a opens and sidewalls 319 b projecting from the periphery of theplate 319 a. A ridge 319 c is formed on the outer surfaces of thesidewalls 319 b to define a peripheral seat 319 d. The peripheral seat319 d receives a filter 321 for removing particles from the ink, orother fluid, contained in the fluid reservoir before the fluid exitsthrough the outlet 313 and ultimately reaches the printhead 200 throughthe closed loop 348.

The filter 321 is used to filter contaminants from the ink so that theink reaching the printhead 200 is substantially contaminant-free. Thefilter 321 is formed of a material which is compatible with the inkstored by the supply cartridge 301 and allows fluid transfer through thefilter but prevents particulate transfer. The use of the “compatible”herein is understood to mean that the material said to be “compatible”with the ink does not break down or alter due to prolonged contact withthe ink and does not change the characteristics of the ink in any way.

Preferably, the filter 321 is a polyester mesh having a pore size of onemicron. Such a mesh filter 321 is preferably mounted on the seat 319 dof the filter compartment 319 by heat staking or the like so that thefilter is sealed about its periphery to the transfer of particles.Providing the supply cartridges with an internal filter obviates theneed for filtration within the closed fluid loop 348.

The internal aperture 311 c of the inlet 317 communicates with theinterior fluid reservoir of the cartridge 301 via a chute 317 a, asillustrated in FIGS. 12 and 15. The internal aperture 311 c of the gasport 315 is formed as a channel 315 a which communicates with theinterior fluid reservoir of the cartridge 301, as illustrated in FIG.14.

The external aperture 311 b of each port 311 is formed as a bore whichreceives a septum 323, as illustrated in FIGS. 13A, 14 and 15, forconnection to tubing. In the exemplary embodiment illustrated in FIGS.16-18B, each septum 323 is provided as a dual septum 325. Each dualseptum 325 is an assembly of two adjacent septa being a pierceableseptum 327 and a slit septum 329, which together form a leak proofbarrier. The leak proof barrier of the dual septa 325 is sealinglypenetrated by a corresponding septum needle 331 to allow fluid flowthrough the ports 311, as illustrated in FIG. 16. Each septum needle 331has a barb 331 a as a connector of tubing of the closed fluid loop 348,for the outlet and inlet 313,317, and of tubing of a gas vent or airchimney 333, for the gas port 315.

The combined pierceable and slit septa provide a redundant disengagebleand compact fluid port and prevent fluid leakage under the followingconditions: (1) before the septum needle has been inserted; (2) whilethe septum needle is inserted; and (3) after the septum needle has beenremoved. These conditions are met in the following manner.

The pierceable septum 327 is assembled as the innermost of the septa327,329 within the bore 311 b of the corresponding port 311 and as suchis in contact with the fluid contained in the cartridge 301 duringtransportation and storage, and during printing. Therefore, thepierceable septum 327 is formed from a resilient material that iscompatible with the fluid in the cartridge 301 and which provides afluid-tight seal against the bore 311 b and the septum needle 331.Preferably, the pierceable septum 327 is formed from an elastomericmaterial, such as low elongation nitrile rubber.

The pierceable septum 327 is circular in form and can be configured asillustrated in the two embodiments illustrated in FIGS. 17A and 17B andin FIGS. 17C and 17D. In both embodiments, the pierceable septum 327 hasan annular ridge or seal 327 a formed at its circumferential edge whichis configured to press against the inner wall of the bore 311 b. Thiscontact pressure deforms the annular ridge 327 a providing a barrier tothe passage of fluid around the circumferential edge of the pierceableseptum 327. This deformation is constrained by forming the portion ofthe pierceable septum 327 interior to the annular ridge 327 a as afrustoconical surface 327 b. The surface 327 b provides rigidity of theinner portions of the pierceable septum 327 which prevents roll andde-sealing of the annular seal 327 a. The surface 327 b plateaus at thecentral portion of the pierceable septum 327 which is formed as a thinmembrane 327 c.

Preferably, the elastomeric material of the pierceable septum 327 haslow tear strength. This material selection together with radial scorelines 327 d formed in the membrane 327 c of the first embodimentillustrated in FIGS. 17A and 17B, and stress concentration geometry 327e formed as a groove in the membrane 327 c concentric with the centralpoint of the membrane 327 c of the second embodiment illustrated inFIGS. 17C and 17D, make piercing of the membrane 327 c easier, with lessstretch and lower required force, when the septum needle 331 pierces orpunctures the pierceable septum 327 during first insertion. After beingpunctured, the elastomeric material of the pierced surface 327 bmaintains a compressive grip around the inserted septum needle 331 whichminimizes communication of fluid across the pierced boundary.Accordingly, the materially compatible resilient seal provided by thepierceable septum 327 prevents fluid leakage under at least theafore-mentioned conditions (1) and (2). A suitable elastomeric materialof the pierceable septum 327 is low elongation nitrile rubber.

The slit septum 329 is assembled as the outermost of the septa 327,329within the bore 311 b of the corresponding port 311 and as such is notin contact with the fluid contained in the cartridge 301 duringtransportation and storage. Therefore, the material of the slit septum329 does not need to be fully compatible with the fluid contained in thecartridge 301. However, the slit septum 329 is required to provide afluid-tight seal against the bore 311 b and the septum needle 331, andis therefore also preferably formed from an elastomeric material.

The slit septum 329 is circular in form, as illustrated in FIGS. 18A and18B, and has two redundant annular ridges or seals 329 a formed at itscircumferential edges which are configured to press against the innerwall of the bore 311 b. This contact pressure deforms the annular ridges329 a providing a barrier to the passage of fluid around thecircumferential edges of the slit septum 329. The central portion of theslit septum 329 has a slit 329 b which is closed and sealed by thecontact pressure created by the compression of the annular seals 329 aso that fluid is prevented from leaking through the closed slit 329 b.The septum needle 331 is passed through the slit 329 b and on throughthe piercable membrane 327 c of the pierceable septum 327 during firstinsertion. After insertion, the elastomeric material about the slit 329b maintains a compressive grip around the inserted septum needle 331which minimizes communication of fluid across the slit boundary.Further, after withdrawal of the septum needle 331 the elastomericmaterial of the slit 329 b recloses the slit 329 b which re-seals theslit septum 329.

The slit septum 329 has an annular detent 329 c between the two annularseals 329 a which provides a volume into which the elastomeric materialof the septum deforms when the septum needle 331 is inserted through theslit 329 b. Accordingly, the possibly materially incompatible resilientseal provided by the slit septum 329 prevents fluid leakage under all ofthe afore-mentioned conditions (1), (2) and (3). A suitable elastomericmaterial of the slit septum 329 is isoprene.

The superior sealing properties of the slit septa means that thematerial of the pierceable septa can have poor elastomeric properties,e.g., low tear strength, which increases the range of availablematerials which can be chosen to provide good compatibility with thefluid contained by the supply cartridge. For example, for the inks usedby the MEMJET™ printers of the Applicant, only elastomeric sealingmaterials having poor elastomeric properties are compatible with theinks in terms of swell, low particle shedding, and other desiredcharacteristics. If single septa constructed of such poor elastomericproperty materials were used, fluid leakage can occur around the outersurface of the septum or along the surfaces penetrated by the septumneedle, because the elastomeric material does not conform well to thesurfaces that they are sealing against. Thus, by using the dual septa325, each port 311 is able to function as a reliably sealed fluid porteven when the fluid contained in the cartridge 301 is materiallyincompatible with one of the two elastomeric seals formed by the dualsepta 325. Furthermore, the dual septa 325 provide multiple redundantsealing surfaces to prevent fluid leakage before, during and after useof the fluid supply cartridge.

In the illustrated example, there are a total of three redundant annularseals around the outer edges of the two septa 327,329, and two redundantseals around the inserted septum needle 331. However, other arrangementsare possible having different numbers of redundant external and internalseals, so long as the redundancy reduces the likelihood of fluid leakageat different points during the life cycle of the seal

The dual septum 325 of the gas port 315 is connected to a vent line 335of the gas vent 333. The vent line 335 is in the form of tubingconnected to the barb 331 a of the septum needle 331 at one end and to afilter 337 at the other end. The filter 337 is preferably formed of ahydrophobic material, such as ePTFE, so that air exclusive of watervapor and the like is able to enter the vent line 335 from the ambientenvironment. Preferably, the hydrophobic material of the filter 337 isexpanded polytetrafluoroethylene (ePTFE, known as Gore-Tex® fabric)which has these gas transit properties. The use of the term“hydrophobic” herein is to be understood as meaning that any liquid, notonly water, is repelled by the material which is said to be“hydrophobic”.

The amount of fluid within the supply cartridge is monitored by asensing arrangement 340. The sensing arrangement 340 senses the level offluid contained within the supply cartridge and outputs the sensingresult to the control electronics 802 of the printer 100. For example,the sensing result can be stored in a quality assurance (QA) device 342of the supply cartridge which interconnects with a QA device of thecontrol electronics 802, as described in previously referenced andincorporated US Patent Application Publication No. 20050157040.

In the illustrated embodiment of FIGS. 9-12, the sensing arrangement 340has a prism and associated sensor incorporated in the lid 305 of thesupply cartridge at a position which accords to a fluid level providingthe predetermined fluid containing capacity of the supply cartridge. Asunderstood by one of ordinary skill in the art in such a sensingarrangement, the sensor emits light of a certain wavelength into theprism and detects returning light and the wavelength of the returninglight.

When fluid is present in the supply cartridge at the level providing thepredetermined fluid containing capacity (herein termed “full level”),the light emitted by the sensor is refracted by the prism back to thesensor as returning light at a first wavelength. In this case, thesensing arrangement 340 provides a signal which indicates a “full” fluidlevel to the control electronics 802.

When fluid is present in the supply cartridge at a first level less thanthe full level (herein termed the “low level”), the light emitted by thesensor is refracted by the prism back to the sensor as returning lightat a second wavelength different than the first wavelength. In thiscase, the sensing arrangement 340 provides a signal which indicates a“low” fluid level to the control electronics 802.

When fluid is present in the supply cartridge at a second level lessthan the first level (herein termed the “out level”), the light emittedby the sensor passes through the prism such that no returning light issensed by the sensor. In this case, the sensing arrangement 340 providesa signal which indicates an “out” fluid level to the control electronics802.

The drawing of ink from the supply cartridge into the closed loop 348reduces the level of ink within the supply cartridge from the full levelto the low level and then the out level. Relaying of this ink levelreduction to the control electronics 802 allows printing by theprinthead 200 to be controlled to eliminate low quality prints, such aspartially printed pages and the like.

For example, at the full indicator, the control electronics 802 allowsnormal printing to be carried out. At the low ink level indicator, thecontrol electronics 802 allows reduced capacity printing to be carriedout, such as subsequent printing of only a certain number of pages ofcertain ink quantity requirements. And at the out level indicator, thecontrol electronics 802 prevents further printing until the supplycartridge is refilled or replaced with a full cartridge, such as throughprompting of a user of the printer 100.

Upon depletion, the supply cartridges 301 are disconnected from thesystem 300 at the ports 311, either replaced or refilled either in situor remote from the system 300, and then reconnected to the system 300.

In the illustrated embodiment, refilling of the supply cartridge 301 isprovided by connecting a refill port 344 in the lid 305 of the supplycartridge 301 with a refilling station or the like. For example, therefill port 344 may comprise a ball valve 346, as illustrated in FIG. 9,or other valve arrangement, which is actuated to open by the refillingstation and refilling is carried out under gravity.

The supply cartridges 301 have a slim and low profile. In theillustrated embodiment, the supply cartridges have a height of about 24millimeters. This enables the supply cartridges 301 to be stacked in theprinter housing 101 in the layout illustrated in FIGS. 6 and 21, whichdisposes the supply cartridges 301 containing different ink colors atdifferent levels to minimize ink color mixing.

In the illustrated layout, five supply cartridges 301 are stacked in anarray having three columns and three rows. The five supply cartridges301 include two black ink supply cartridge 301K, a cyan ink supplycartridge 301C, a magenta ink supply cartridge 301M and a yellow inksupply cartridge 301Y.

In FIG. 19, the printing or ejection face of the printhead 200containing the ejection surfaces of the ejection nozzles is defined as areference at zero millimeters. As illustrated, the black ink cartridges301K are disposed at the lowest row of the array in the first and thirdcolumns of the array so that the upper surfaces of the black inkcartridges 301K are at about −90 millimeters relative to reference ofthe printing surface. The magenta and cyan ink cartridges 301M,301C aredisposed at the middle row of the array in the first and third columnsof the array so that the upper surfaces of the magenta and cyan inkcartridges 301M,301C are at about −65 millimeters relative to referenceof the printing surface. The yellow ink cartridge 301Y is disposed atthe highest row of the array in the second column of the array so thatthe upper surface of the yellow ink cartridge 301Y is at about −55millimeters relative to reference of the printing surface.

By arranging the different ink color cartridges in the layout of FIG.19, the black ink channels have a lower backpressure than the magenta,cyan and yellow ink channels, and the magenta and cyan ink channels havea lower backpressure than the yellow channel. The result is that on theprinthead 200, in the presence of fibers, dust, ink or othercontaminants, if a fluid path is formed between any two ink colorchannels and fluid begins to flow from one ink channel to anothercausing color mixing, the flow will be pulled towards the magenta andcyan ink channels from the yellow ink channel and towards the black inkchannels from the magenta, cyan and yellow ink channels. Because theseflow directions allow the black ink to absorb the other mixed ink colorsthe effects of color mixing in the printhead 200 are reduced since thecolor mixing is less noticeable in the printed product than if all inkcolors contained similar back pressure levels.

In order to ensure that the correct ink color cartridge is inserted atthe correct position in the layout, the lid 305 of each supply cartridge301 is provided with a lockout plate 350 which has a feature 350 a at aposition on the lockout plate 350 corresponding to the ink colorcontained in the supply cartridge 301. The features 350 a engage withrespective features on the printer housing 101 at positionscorresponding to the ink color in the layout, so that the correct inkcolor is supplied to the correct ink channel of the fluid distributionsystem 300 and printhead 200. The lids 305 of the supply cartridges 301are further provided with locating and alignment features 365 whichlocate the supply cartridges 301 with mating features on the printerhousing 101 thereby aligning the supply cartridges for proper fluid flowinto the closed fluid loop and vent lines.

In the above-discussed arrangement two black ink supply cartridges areused for a CYMKK ink channel configuration, however more or less of theink channels could provide the same ink color depending on the printerapplication.

In the illustrated embodiment of the fluid distribution system 300 ofFIGS. 6 and 7, a multi-channel gas vent assembly 333 is provided for thefive supply cartridges 301 of the five ink channels. The multi-channelgas vent assembly 333 is illustrated in FIGS. 20 and 21. The gas ventassembly 333 has a body 339 which is mounted to the printer housing 101.As illustrated, the body 339 is formed as a box, one sidewall 339 a ofwhich is formed with barbs 341 as connectors for the tubing of the ventlines 335 of the supply cartridge gas ports 315.

The body 339 has a number of discrete chambers 343 (the numbercorresponds to the number of ink channels of the printhead 200 which inthe illustrated embodiment is five) defined on one side of the box bythe sidewall 339 a, sidewalls 339 b, 339 c and 339 d, internal walls 339e, and a surface 339 f. The remaining open side of each of the chambers343, as illustrated in FIG. 20, can be sealed by either a further wallof the body 339 or a sealing film or the like mounted on the body 339(not illustrated for clarity).

Each chamber 343 has a hole 343 a through the sidewall 339 a of the body339 which communicates with the hollow interior of a corresponding oneof the connectors 341, thereby defining transfer ports of the gas ventassembly 333. In this way, fluid is communicated between the chambers343 and the corresponding vent lines 335, and ultimately thecorresponding supply cartridges 301 via the gas ports 315.

The surface 339 f in each chamber 343 is formed with a recess 345 inwhich apertures 347 are formed through the surface 339 f. The filters337 are sealingly received in the recesses 345 so as to provide ahydrophobic filter between the chambers 343 and the apertures 347. InFIG. 20, one of the filters 337 is omitted to allow illustration of therecess 345 and aperture 347 of one of the chambers 343.

Each aperture 347 communicates with a series of compartments 349 definedon the other side of the box by the sidewalls 339 a-339 d, internalwalls 339 g, and the surface 339 f. The remaining open side of each ofthe compartments 349, as illustrated in FIG. 21, can be sealed by eithera further wall of the body 339 or a sealing film or the like mounted onthe body 339 (not illustrated for clarity).

The series of compartments 349 corresponding to a particular aperture347, and therefore a particular chamber 343, are fluidically linked bytortuous or serpentine paths 349 a. Further, as illustrated in thecut-away partial detailed view of FIG. 21, the final compartment 349 bof each compartment series is fluidically open to atmosphere via anothertortuous path 349 c. In the illustrated embodiment, there are fivecompartments 349 in each compartment series, however more or lesscompartments are possible.

This arrangement for each channel of the gas vent assembly 333 providesa gas path between the vent line 335 and the external atmosphere via thecorresponding chamber 343, filter 337 and series of compartments 349.The gas path allows gases, such as ambient air and internal vapors ofthe supply cartridge 301 formed by volatiles evaporated from thecontained ink, to pass into and out of the supply cartridge 301. Thisgas transit, together with mounting the gas vent assembly 333 to theprinter housing 101 so that the connectors 341 are at the lower side ofthe body 339, allows the internal gas pressure of the supply cartridge301 to be equalized to external ambient conditions, which providesconsistent fluid flow through the outlet and inlet ports 313,317 of thesupply cartridges 301.

The hydrophobic nature of the filters 337 together with the fluidcontaining volume provided by the chambers 343 prevents ink which mayoverflow from the supply cartridge 301 from passing into thecompartments 349. This ensures that air at controlled pressure is alwayspresent in the gas vent 333 which enables the gas pressure equalization,and that a volume for the evaporated volatiles is provided. In theillustrated embodiment, the volume provided by each series ofcompartments 349 is about 15 cubic centimeters, the tortuous path lengthto area ratio provided by the relatively long and narrow tortuous gaspaths of each compartment 349 is about 60 mm⁻¹, and the ink overflowvolume provided by each chamber 343 is about 12.6 cubic centimeters.Accordingly, the gas vent assembly has cascading chambers with long andnarrow serpentine gas paths to gas vents which are protected by a liquidbarrier.

Another embodiment of the fluid distribution system 300 incorporates analternative embodiment of the multi-channel gas vent assembly 333. Inthis alternative embodiment of the multi-channel gas vent assembly 333fluid overflow management is provided such that overflowing fluid fromthe supply cartridges 301 at volumes greater than can be contained inthe ink overflow volume provided by the chambers 343 is able to exit thegas vent assembly 333. The fluid distribution system 300 of thisembodiment is illustrated schematically for a single fluid channel inFIG. 22A, and the alternative multi-channel gas vent assembly 333 isillustrated in FIGS. 22B and 22C.

As illustrated, each chamber 343 has a further hole 343 b through thesidewall 339 d of the body 339 which communicates with the hollowinterior of a corresponding barb 351 as a connector for tubing of awaste fluid line 353. The waste fluid lines 353 preferably feed into asingle tube 353 a which drains the overflowed ink, or other printingfluids, into a fluid collection tray 601 of the maintenance system 600,which is described in detail later.

A check valve 355 is preferably provided at each connector 351 so thatback flow of ink from the waste fluid lines 353 to the chambers 343 isprevented. That is, as is understood by one of ordinary skill in the artin the art, check valves are one-way valves which allow free fluid flowwhen positive differential fluid pressure between the upstream anddownstream sides of the check valve above the cracking pressure of thecheck valve is present but disallow, or check, backflow from thedownstream side to the upstream side when negative differential fluidpressure between the upstream and downstream sides is present. The checkvalve is preferably an elastomeric duckbill check valve, as illustratedin FIG. 22B.

In a further alternative embodiment of the fluid distribution system 300the multi-channel gas vent assembly is replaced by fluid overflow bufferunits 354 to provide fluid overflow management from the supplycartridges 301. The fluid distribution system 300 of this embodiment isillustrated schematically for a single fluid channel in FIG. 22D, andthe fluid overflow buffer units 354 are illustrated in FIGS. 22E-22H.

The buffer units 354 are configured to store ink that may overflow fromthe full or partially filled supply cartridges 301 due to volumetricexpansion of air within the supply cartridges 301 caused by effects suchas ambient temperature changes and barometric variation in theatmosphere. In the case of severe overflow, the buffer units 354 providea discharge path that allows the ink to flow from the buffer units 354into the fluid collection tray 601.

The layout of the supply cartridges 301 of FIG. 19 is accommodated forby configuring each buffer unit 354 with a body 356 defining twochambers 358 for capture of ink from two of the supply cartridges. Thisalso allows simple and reproducible manufacture of the buffer units 354independent of the layout employed for the supply cartridges. In thearray of five of the supply cartridges 301 illustrated in FIG. 22E,three buffer units 354 each having upper and lower chambers 358 arearranged with a first buffer unit 354 servicing the magenta and blackink supply cartridges 301M,301K in the first column of the array, asecond buffer unit 354 servicing the yellow ink supply cartridge 301Y inthe second (middle) column of the array, and a third buffer unit 354servicing the cyan and black ink supply cartridges 301C,301K in thethird column of the array.

A single buffer unit 354 is illustrated in detail in FIGS. 22F-22H. Thechambers 358 of the buffer unit 354 are formed as open compartments ofthe body 356 and are enclosed by a cover 360. The buffer units 354 areformed of a plastics material inert to ink, and are preferably molded tocontain the chambers 358 and associated elements as discussed below. Thecovers 360 are formed of material which is fluid tight, and arepreferably hermetically sealed on the body 356.

Each chamber 358 has a channel 362 which has a port 364 for connectionto the gas port 315 of the corresponding supply cartridge 301. The ports364 are configured to either connect directly to the barbs 331 a of theseptum needles 331 or to tubing connected to the barbs 331 a of a gasvent. Either way, the channels 362 form part of the vent lines 335 fromthe supply cartridges 301 through which fluid flows between the supplycartridge 301 and buffer unit 354. The channels 362 are dimensioned sothat ink ‘slugs’ are pulled through the channels 362 without gas and inkpassing each other. That is, the inner diameter of the cylindricalchannels 362 is sufficiently small so that, with the given wetting anglebetween the plastic channel wall and the ink meniscus, ink and gasbubbles cannot be trapped in the channel as ink is pulled through duringprinting. At the same time, the inner diameter of the cylindricalchannels 362 is sufficiently large so as not to restrict the flow of inkduring printing which could otherwise cause a undesired ink pressuredrop. In particular, an inner diameter of the channels 362 of about twomillimeters provides this function. In this manner, no ink is strandedin the channels 362 and a clear gas path is created once ink drains outof the buffer unit 354 during printing for normal gas venting from thesupply cartridges 301.

Each channel 362 has a U-shaped drain path 366 through which fluid flowsinto and out of the respective chamber 358. Each drain path 366 has aninner diameter similar to that of the channels 362, e.g., about twomillimetres, so that ink ‘slugs’ are pulled through the drain path 366without gas and ink passing each other. The bottom walls 368 of thechambers 358 are sloped along two axes so that the lowest point in eachchamber 358 is at the location of the respective U-shaped drain path366. This sloping of the bottom walls 368 is seen most clearly in FIG.22G. In this way, any ink that overflows into the chamber 358 will flowtowards this point as it drains.

Each chamber 358 is configured with sufficient volume to capture themaximum amount of ink that will overflow from the supply cartridges 301.Ink that overflows into the chambers 358 is stored at a lower elevationthan the connected gas port 315 of the supply cartridge 301 so that thesupply cartridge 301 can be removed from the system 300 without inkleaking from the buffer unit 354 through the gas port 315. In order toaccount for overfilling of a chamber 362 of the buffer unit 354 with inkfrom the connected supply cartridge 301, an overflow port 370 isprovided adjacent the top wall 372 of each chamber 358 through whichexcess ink is able to overflow from the buffer unit 354 into the fluidcollection tray 601.

The chambers 358 are also configured to serve as gas reservoirs whichcontain a volume of gas and prevent the contained gas from exiting tothe environment via the overflow ports 370 when the chambers 358 are notcompletely full of ink. This gas warehousing reduces the loss ofvolatile components in the ink when gas in the supply cartridgesvolumetrically expands and flows therefrom or through slow evaporationwhich could otherwise change the composition of the ink. The inkcomposition should be kept constant so to not affect print quality orthe firing properties of the ink drops as they are ejected from theprinthead. This is achieved by forming each overflow port 370 with adischarge path 374 to the outside of the buffer unit 354 which has along and narrow serpentine form enclosed by a cover 360. The serpentinepaths 374 prevent humid air in the chambers 358 from diffusing to theoutside environment and therefore serves as diffusion barriers betweenthe buffer unit 354 and the outside environment. The inner diameter ofthe serpentine paths 374 is dimensioned similar to that of the channels362 so that ink ‘slugs’ are pulled through the serpentine paths 374without gas and ink passing each other. In this manner, no ink isstranded in the serpentine paths 374 and the serpentine paths 374 willclear automatically as printing occurs and the ink is drawn up theserpentine paths 374 and into the chambers 358. Isolation walls 376 areformed within the chambers 358 about the overflow ports 370 so as toprevent ink from leaking into the serpentine paths 374 if the printer isturned on its side and there is ink in the buffer unit 354.

Each closed loop 348 provides a fluid path between the correspondingsupply cartridge 301 and the printhead 200. This fluid path is providedas a closed loop so that fluid can be primed into the fluid path and theprinthead from the supply cartridge, the primed fluid can be printed bythe printhead and the fluid can be de-primed from the printhead and thefluid path back to the supply cartridge so that de-primed fluid is notwasted, which is a problem with conventional fluid distribution systemsfor printers. The closed loop 348 also allows periodic recirculation offluid within the fluid distribution system 300 to be carried out so thatthe viscosity of the fluid, such as ink, is retained within specifiedtolerances for printing.

In the embodiment of FIG. 8, the closed loop 348 is comprised of pluralfluid lines. A print fluid line 380 is provided between the supplycartridge outlet 313 and the printhead 200. A pump fluid line 382 isprovided between the printhead 200 and the supply cartridge inlet 317.The fluid lines of the closed loop 348 are in the form of tubing, andare preferably tubing which exhibits low shedding and spallation in anink environment. Thermoplastic elastomer tubing is therefore suitable,such as Norprene® A-60-G. However, one of ordinary skill in the artunderstands that other types of tubing can be used. The tubing of theclosed loop 348 is connected to the printhead 200 by supply couplings388. The supply couplings 388 and the manner of their connection isdescribed in detail in the incorporated description of the Applicant'sU.S. Provisional Patent Application No. 61/345,552 (Docket No.KPF001PUS).

A pump 378 is provided on the pump fluid line 382. The pump 378 ispreferably a peristaltic pump so that contamination of the pumped ink isprevented and so that pumping amounts of about 0.26 millilitres perrevolution of the pump are possible. However, one of ordinary skill inthe art understands that other types of pumps can be used.

A valve arrangement 367 is provided on the print fluid line 380, asillustrated in FIG. 8. The valve arrangement 367 has a 2-way pinch valve369 on the print line 380 and a vent line 371 of a gas vent 373 (hereintermed “de-prime vent”), and a check valve 375 on the vent line 371. Thevent line 371 has one end connected to the check valve 375 and a filter377 of the de-prime vent 373 disposed at the other end. The valvearrangement of the present embodiment is provided in place of the pinchvalve embodiment of the incorporation description of the co-filed USprovisional patent application filed under Applicant's U.S. ProvisionalPatent Application No. 61/345,552 (Docket No. KPF001PUS).

The above discussion has been made in relation to a fluid distributionsystem for a single fluid channel, e.g., an ink of one color, arrangedas shown in FIG. 8 (or FIGS. 22A and 22D). In order to deliver more thanone fluid to the printhead 200 or multiple printheads each printing oneor more ink colors, the fluid distribution system 300 is replicated foreach fluid. That is, as discussed above, separate supply cartridges 301for each fluid are provided which are connected to the printhead 200 viaan associated closed fluid path loop 348.

Certain components of these separate systems can be configured to beshared. For example, the supply couplings 388, the valve arrangement 367and the pump 378 can each be configured as multiple fluid channelcomponents, and a single or separate de-prime vents 373 can be used forthe multi-channel valve arrangement 367. An exemplary arrangement ofthese multiple fluid paths is illustrated in FIGS. 6 and 7.

For an exemplary printhead 200 having five ink flow channels, e.g.,CYMKK or CYMKIR, as discussed above, the pump 378 is a five channel pumpwhich independently pumps the ink in each channel. The structure andoperation of such a multi-channel pump is understood by one of ordinaryskill in the art.

Using the multi-channel valve arrangement 367 facilitates efficientmanufacture and operation of this component. The multi-channel valvearrangement 367 may be arranged as a multi-channel 2-way pinch valve 369as illustrated FIGS. 23A-27C.

The multi-channel 2-way pinch valve 369 has five connectors 379,respectively labelled 379-1, 379-2, 379-3, 379-4 and 379-5, in seriesalong a body or housing 381, and five connectors 383, respectivelylabelled 383-1, 383-2, 383-3, 383-4 and 383-5, also in series along thehousing 381. The connectors 379 and 383 are connected to the tubing ofthe five print lines 380 and the connectors 383 are further connected tothe tubing of the five vent lines 371.

Elongate pinch elements 385 and 387 are disposed on the housing 381respectively extending across the connected tubing of the connectors 379and 383. The pinch elements 385, 387 have bars 385 a,387 a at eitherlongitudinal end which are slidingly received within channels 381 a ofthe housing 381. The bars 385 a,387 a are configured to be slid withinthe channels 381 a so that the pinch elements 385,387 are brought intoand out of contact with the print and vent line tubing, respectively, toselectively “pinch” the tubing and thereby selectively obstruct or allowfluid flow through the print and vent lines, respectively. The pinchelement 385 is termed herein as the “print line pinch element” and thepinch element 387 is termed herein as the “vent line pinch element”.

This sliding movement of the pinch elements 385,387 is provided by apinch drive arrangement 389 disposed in the housing 381. The pinch drivearrangement 389 has a cam shaft 391 rotatably mounted to the housing381, two eccentric cams 393 fixedly mounted in parallel on the cam shaft391, springs 395 disposed between, and interconnecting, the pinchelements 385,387 and the shaft 391, and a sensing arrangement 397.

The shaft 391 has a square spline section 391 a which cooperates with aninternal corresponding square spline form 393 a of the cams 393 so thatthe square spline form 393 a conforms with and fits snugly onto thesquare spline section 391 a. Each cam 393 further has an arm or pokayoke 393 b which engages with, and is retained by, a recess or groove391 b and a poka yoke feature 391 c of the shaft 391, as illustrated inFIGS. 24-26. This multiple cooperation ensures that the cams 393 areaccurately rotated with rotation of the shaft 391.

In the illustrated embodiment, the springs 395 are provided as two bentsprings, however separate springs could be equally provided. The bentsprings 395 each have one spring section 395 a connected to a pin 385 bat a corresponding longitudinal end of the pinch element 385 and asecond spring section 395 b connected to a pin 387 b at a correspondinglongitudinal end of the pinch element 387. A central section 395 c ofeach bent spring 395 which is central to the two spring sections 395a,395 b is mounted over the shaft 391 and held thereon by a mountingmember or bushing 399. Each mounting member 399 is mounted on the shaft391 at a respective cylindrical section 391 d of the shaft 391 by snapfitting or the like so that the mounting members 399, and therefore thesprings 395, are not rotated with the shaft 391. The spring sections 395a,395 b are configured to bias the pinch elements 385,387 toward theshaft 391 and the two springs 395 are provided as disposed so that thepinch elements 385,387 are biased parallel to the shaft 391. The springs395 are preferably compression springs.

The bars 385 a,387 a of the pinch elements 385,387 constitute camfollowers having engagement faces 401 which are engaged with, andfollow, the eccentricity of the cams 393 due to the bias provided by thesprings 395. The eccentric profile of the cams 393 includes a roundedsection 403 and a beak section 405 as illustrated in FIGS. 27A-C, whichcause the pinch elements 385,387 to be moved relative to the housing 381so as to selectively pinch or not-pinch the print and vent line tubingthereby providing the following three valve states of the 2-way pinchvalve 369.

When the 2-way pinch valve 369 is in the fully closed (dual pinch) stateillustrated in FIG. 27A both the print line tubing and the vent linetubing are pinched. The fully closed state is provided by rotating theshaft 391 so that the rounded sections 403 of the cams 393 are engagedwith the engagement faces 401 of the bars 385 a,387 a of the pinchelements 385,387 which causes the pinch elements 385,387 to be forcedtoward the shaft 391 with the bias of the springs 395.

When the 2-way pinch valve 369 is in the first partially closed (printline pinch) state illustrated in FIG. 27B the print line tubing ispinched whilst the vent line tubing is not pinched. The first partiallyclosed state is provided by rotating the shaft 391 so that the roundedsections 403 of the cams 393 are engaged with the engagement faces 401of the bars 385 a of the print line pinch element 385 which causes theprint line pinch element 385 to be forced toward the shaft 391 with thebias of the spring sections 395 a whilst the beak sections 405 of thecams 393 are engaged with the engagement faces 401 of the bars 387 a ofthe vent line pinch element 387 which causes the vent line pinch element387 to be forced away from the shaft 391 against the bias of the springsections 395 b.

When the 2-way pinch valve 369 is in the second partially closed (ventline pinch) state illustrated in FIG. 27C the vent line tubing ispinched whilst the print line tubing is not pinched. The secondpartially closed state is provided by rotating the shaft 391 so that therounded sections 403 of the cams 393 are engaged with the engagementfaces 401 of the bars 387 a of the vent line pinch element 387 whichcauses the vent line pinch element 387 to be forced toward the shaft 391with the bias of the spring sections 395 b whilst the beak sections 405of the cams 393 are engaged with the engagement faces 401 of the bars385 a of the print line pinch element 385 which causes the print linepinch element 385 to be forced away from the shaft 391 against the biasof the spring sections 395 a.

The pinch drive arrangement 389 further has a motor 407 which is coupledat one end of the shaft 391 by a motor coupling 409 to provide therotation of the shaft 391. The motor 409 is preferably a stepper motorwith bi-directional operation so that the shaft 391 and the cams 393 arerotatable in both clockwise and counter-clockwise directions to effectmovement of the pinch elements 385,387 relative to the shaft 391 andprint and vent line tubing. However, other arrangements and motor typesare possible.

In the illustrated embodiment, the motor coupling 409 is provided with aprojection or flag 409 a with which sensors A and B of the sensingarrangement 397 cooperate to sense a rotated position of the shaft 391.The sensors A and B are preferably optical interrupt elements and theprojection 409 a is preferably a semi-circular disc dimensioned to passbetween an optical emitter and optical sensor of the optical interruptelements so as to either obstruct or leave open the optical path betweenthe optical emitter and sensor. However, other sensing or operationalarrangements for sensing the rotated position of the shaft 391 arepossible.

The optical interrupt elements A and B are disposed as illustrated inFIGS. 27A-27C so that when the 2-way pinch valve 369 is in the dualpinch state the projection 409 a obstructs the emitter and sensor ofonly the optical interrupt element A (see FIG. 27A) and when the 2-waypinch valve 369 is in the print or vent line pinch states the projection409 a obstructs the emitter and sensor of only the optical interruptelement B (see FIGS. 27B and 27C).

The sensing arrangement 397 outputs the sensing results of the sensorsA,B to the control electronics 802 of the printer 100 so that operationof the motor 409 can be controlled by the control electronics 802 toselect predetermined rotated positions of the cams 393 for selecting thedual, print line and vent line pinch states. Accordingly, the pinchelements 385,387 and the pinch drive arrangement 389 form a selectiondevice for selecting these valve states by selectively closing andopening the multiple paths of the 2-way pinch valve. The particularmanner in which the pinch drive arrangement 389 is operated to selectand transition between the dual, print line and vent line pinch statesis shown in Table 1. In Table 1, “CW” designates clockwise rotation ofthe motor coupling and therefore cam shaft and cams, “CCW” designatescounter-clockwise rotation of the motor coupling and therefore cam shaftand cams, “A” designates sensor A, and “B” designates sensor B.

TABLE 1 pinch drive arrangement operation for 2-way pinch valve statetransitions STATE TRANSITION OPERATION vent line pinch to dual pinch CWuntil A is obstructed vent line pinch to print line CW until B is open;then pinch CW until B is obstructed dual pinch to print line pinch CWuntil B is obstructed dual pinch to vent line pinch CCW until B isobstructed print line pinch to vent line CCW until B is open; then pinchCCW until B is obstructed print line pinch to dual pinch CCW until A isobstructed unknown position to dual pinch if A is open, CW until A isobstructed; if A is obstructed, CCW until A is open unknown position toprint line if B is open, CW until B is obstructed; pinch if B isobstructed, CCW until B is open unknown position to vent line if B isopen, CCW until B is obstructed; pinch if B is obstructed, CW until B isopen

In the above described embodiment of the 2-way pinch valve, the housing381, the motor coupling 409 a, the pinch elements 385,387, the cams 393and the spring mounting members 399 are each preferably formed of aplastics material, such as 20% glass fibre reinforced acrylonitrilebutadiene styrene (ABS) for the housing and motor coupling, 30% glassfibre reinforced Nylon for the pinch elements and Acetal copolymer (POM)for the cams and spring mounting members. Further, the cam shaft 391 andsprings 395 are preferably formed of metal, such as stainless steel forthe cam shaft and music wire for the springs.

The check valves 375 may be provided as mechanical one-way valves. Thestate of a mechanical check valve 375 may be controlled by the controlelectronics 802 of the printer 100 so that in the closed state of thecheck valve 375, the vent line 371 is isolated from the print line 380,and in the open state of the check valve 375, air can enter the system300 via the de-prime vent 373. In such an example, the check valve 375has a structure and function well understood by one of ordinary skill inthe art. A single check valve 375 can be provided for a single de-primevent 373 in the system 300, or if the system has multiple de-prime vents373, such as five for the five ink channels discussed earlier, aseparate check valve 375 can be provided for each de-prime vent 373.

In the illustrated embodiment of FIG. 24, the check valves 375 areprovided as an integral part of the 2-way pinch valve 369 structure aspassive elastomeric duckbill check valves 375 within the tubing of thevent lines 371 between the pinch element 387 and the de-prime vent 373.Duckbill check valves provide reliable backflow prevention at lowpressure differentials. The duckbill check valves 375 of the illustratedembodiment are arranged to allow air to flow through the filters 377 tothe corresponding vent lines 371 when the vent lines 371 are un-pinchedby the pinch element 387 whilst preventing ink from flowing from thevent lines 371 to the filters 377 when the vent lines 371 are bothun-pinched and pinched by the pinch element 387.

Positioning passive check valves in this manner prevents inkaccumulating in the vent lines due to repeated pressure priming of theprinthead (discussed later) in which small quantities of ink may bepushed past the pinched sections of the vent line tubing by the highfluid pressures used in the pressure priming. This accumulated ink couldotherwise have adverse effects on the hydrophobic filter or cause inkleaks through the de-prime vent. The cracking pressure of each of theduckbill check valves 375 is sufficiently low so as to preventinterference with their function of de-priming the printhead 200(discussed later).

The operations performed by the fluid distribution system 300 at thethree valve states of the 2-way pinch valve 369 of the valve arrangement367 are shown in Table 2 with respect to the print lines 380 and thevent lines 371. In Table 2, an “X” indicates that the associated stateis selected and a blank indicates that the associated state is notselected. It is noted that when the vent lines 371 are open, the checkvalves 375 are also open and when the vent lines 371 are closed, thecheck valves 375 are also closed, due to the above-described nature anddisposition of the check valves 375.

TABLE 2 2-way pinch valve states PRINT LINES VENT LINES OPERATION openclosed open closed PRIME X X PRINT X X STANDBY X X PULSE X X DEPRIME X X

The manner in which these state settings of the valve arrangement 367are used is now discussed.

At first power up of the printer and at times subsequent to first powerup when priming is required (such as at start up of the printer), thefluid distribution system 300 is primed by first performing a heavyflush and then a light pressure prime so that air in the printhead isdisplaced to the supply cartridges via their inlets, and so that it isensured that the pump is fully wetted prior to beginning any furthervolumetric pumping procedures. For the heavy flush, the 2-way pinchvalve is set to PRIME and the pump is operated in the clockwisedirection for 50 to 100 revolutions at 200 rpm so that ink is moved fromthe supply cartridge outlets to the supply cartridge inlets via theprint lines, printhead and pump lines thereby priming each closed loop.In the light pressure prime, the 2-way pinch valve is set to PULSE andthe pump is operated in the counterclockwise direction for tworevolutions at 325 rpm to cause ink to be egested from the nozzles ofthe printhead and then the maintenance system 600 is operated to wipethe ejection face of the printhead so as to remove the egested ink, asdescribed later or in the incorporated description of the Applicant'sU.S. Provisional Patent Application No. 61/345,559 (Docket No.KPM001PUS).

-   -   Then, the 2-way pinch valve is set to PRINT.

It is important to note in this pressure prime procedure that theprinthead wipe is performed before moving the 2-way pinch valve from thePULSE setting to the PRINT setting. This is to prevent the ink on theejection face of the printhead being sucked into the nozzles due to thenegative fluid pressure at the nozzles which is established when thesupply cartridge is reconnected to the printhead via the print line.Further, a delay of at least 10 seconds after finishing the wipingoperation is observed before moving the 2-way pinch valve from the PULSEsetting to the PRINT setting so as to minimize color mixing which theApplicant has found can result from the pressure priming The spitting of5000 drops from each nozzle of the printhead before setting the valve toPRINT has been found by the Applicant to sufficiently clear this colormixing. This spitting procedure equates to about 0.35 millilitres of inkbeing spat out by the entire printhead when the ejection drop size ofeach nozzle is about one picoliter.

When printing is to be carried out, a quick flush is periodically firstperformed. In the quick flush, the 2-way pinch valve is set to PRIME andthe pump is operated in the clockwise direction for at least 10revolutions at 200 rpm. Then printing is performed by setting the 2-waypinch valve to PRINT and ejection of ink from the nozzles causes inkflow from the supply cartridges to the printhead via the print lines.After printing, the 2-way pinch valve is set to STANDBY.

A user can request a printhead recovery procedure when printing problemsare encountered. A user can initiate a recovery by selecting a recoveryoperation through a user interface of the printer which is connected tothe control electronics. The recovery procedure defines escalating anddecrementing recovery levels depending on the manner of the recoveryrequest. At the lowest (first) recovery level, the afore-described heavyflush, printhead wipe and spitting operations are performed. At the nexthighest (second) recovery level, the afore-described heavy flush, lightpressure prime, printhead wipe and spitting operations are performed. Atthe highest (third) recovery level, the afore-described heavy flushoperation is performed then a heavy pressure prime is performed followedby the afore-described printhead wipe and spitting operations. In theheavy pressure prime, the 2-way pinch valve is set to PULSE and the pumpis operated in the counterclockwise direction for three revolutions at325 rpm to cause ink to be egested from the nozzles of the printhead

The control electronics 802 includes a register which stores anupdateable setting of the recovery level to be performed upon receipt ofa recovery request. The first recovery level is set upon initial receiptof recovery request. The recovery level setting is incremented to thesecond recovery level and then the third recovery level whenever furtherrecovery requests are received within 15 minutes of each prior recoveryrequest. The recovery level setting is decremented to the next lowestrecovery level depending on which recovery level was most recentlyperformed whenever five print jobs are performed or 15 minutes elapsewithout receipt of a recovery request.

When printing is to be carried out, a quick flush is periodically firstperformed. In the quick flush, the 2-way pinch valve is set to PRIME andthe pump is operated in the clockwise direction for at least 10revolutions at 200 rpm. Then printing is performed by setting the 2-waypinch valve to PRINT and ejection of ink from the nozzles causes inkflow from the supply cartridges to the printhead via the print lines.After printing, the 2-way pinch valve is set to STANDBY.

When the printhead is to be removed from the fluid distribution system300 or the printer is powered down, it is necessary to de-prime theprinthead. In the de-prime procedure, the 2-way pinch valve is set toDEPRIME and the pump is operated in the clockwise direction for 25 to 30revolutions at 100 to 200 rpm to de-prime the print lines, printhead andpump lines by allowing air to pass through the printhead from thede-prime vents which pushes the ink from the print lines, printhead andpump lines into the supply cartridges so that the ink is moved into thepump lines to at least a leak safe location downstream of the pumprelative to the printhead. Then, the 2-way pinch valve is set toSTANDBY, which closes the all of the print and vent lines therebyallowing leak safe removal of the printhead or the like.

The above described values for the pump operation in the various primingand de-priming procedures are approximate and other values are possiblefor carrying out the described procedures. Further, other procedures arepossible and those described are exemplary.

The above described de-prime procedures of the multi-channel valvearrangement clears the printhead of ink with about 1.8 millilitres ofink being left in the printhead, which Was determined by the Applicantthrough relative weight measures of the printhead prior to first primingand after de-priming. This is considered as the dry-weight of theprinthead.

In an alternative embodiment of the fluid distribution system 300 havingthe 2-way pinch valve 369 illustrated in FIG. 28, on demand de-primingof the fluid distribution system 300 is provided. On demand de-primingmay be useful in situations where it is desirable to drain some ink outof the supply cartridge or out of the vent lines of the supplycartridges which can fill with ink due to air expanding in the supplycartridge which can be caused by temperature and barometric changes inthe environment.

The on demand de-primed fluid is purged to the fluid collection tray 601via the vent lines 371 of the valve 369. This is achieved by positioninga purge line 411 on each vent line 371 between the pinch element 387 andthe respective de-prime vent 373. Each purge line 411 terminates with acheck valve 413, such as a passive elastomeric duckbill check valve,which is positioned so that ink can be ejected into the fluid collectiontray 601. This arrangement allows the printhead to be de-primed andprimed on demand with no wasting of ink and no net overflow of ink outof the supply cartridges.

In this alternative embodiment, the printhead is de-primed on demand asfollows. The 2-way pinch valve is set to DEPRIME and the pump isoperated in the clockwise direction for a number of revolutions tode-prime the printhead by allowing a ‘slug’ of air to pass through theprinthead from the de-prime vents. Note that air has been introducedinto the system so that an equal amount of fluid (air or ink) willoverflow into the vent line of the supply cartridges.

The printhead is on demand re-primed by setting the 2-way pinch valve toDEPRIME (i.e., the same setting as during the on demand de-prime) andthe pump is operated in the counter-clockwise direction for the same, ornearly the same, number of revolutions as during the on demand de-primeto force the introduced ‘slug’ of air out through the purge lines 411.This action also pulls the ink or air back into the supply cartridgefrom the vent lines where it would have overflowed during the on demandde-prime. After this procedure, no net ink has been displaced in thefluid distribution system.

The above-described valve arrangements for the fluid distribution system300 is exemplary, and other alternative arrangements are possible toprovide selective fluid communication within the closed fluid loop ofthe system, such as the valve arrangements of the incorporateddescription of the Applicant's U.S. Provisional Patent Application No.61/345,552 (Docket No. KPF001PUS).

The maintenance system 600 is now described. The maintenance system 600is similar in arrangement and operation as the maintenance systemdescribed in the Applicant's U.S. Provisional Patent Application No.61/345,552 (Docket No. KPF001PUS)

The present maintenance system differs from the maintenance system ofthe incorporated description of the Applicant's U.S. Provisional PatentApplication No. 61/345,559 (Docket No. KPM001PUS) in the provision of awiper module having a transfer roller and a scraper, a simplified wastefluid collection arrangement of the maintenance sled and a fluidcollection tray. This and other components of the maintenance system 600are now described in detail. Where suitable, the same reference numeralsfor the same components of the incorporated description of theApplicant's U.S. Provisional Patent Application No. 61/345,559 (DocketNo. KPM001PUS) are herein used.

The maintenance system 600 maintains the printhead 200, and thereby thefluid distribution system 300, in operational order throughout theoperational life of the printhead 200.

After each print cycle of the printhead 200, and during periods ofnon-use of the printhead 200, the maintenance system 600 is used to capthe ejection nozzles of the printhead 200 so as to prevent drying offluid within the nozzles. This reduces problems with subsequent printingdue to blockages in the nozzles.

The maintenance system 600 is also used to clean the afore-mentionedprinting face of the printhead 200, i.e., the surface of the printhead200 containing the printhead ICs 204, by wiping the printhead ICs.Further, the maintenance system 600 is also used to capture fluid whichthe printhead ‘spits’ or egests from the nozzles during priming andmaintenance cycles.

Further, the maintenance system 600 is also used to provide support formedia during printing in a clean manner which minimizes fluid transferonto the media.

Furthermore, the maintenance system 600 stores the ink and otherprinting fluids collected during these functions within the printer 100for later disposal or re-use.

To achieve these functions, the maintenance system 600 employs the fluidcollection tray 601 and a modular maintenance sled 603. The sled 603defines a maintenance unit of the printer 100 and houses severalmaintenance devices or modules each having a different function. In theillustrated embodiment of FIGS. 29 and 30, the maintenance modulesinclude a platen module 604, a wiper module 605 and a capper module 608.The fluid collection tray 601, sled 603 and wiper module 605 of thepresent embodiment are provided in place of fluid collector, sled andwiper module of the incorporated description of the Applicant's U.S.Provisional Patent Application No. 61/345,559 (Docket No. KPM001PUS),whilst the platen and capper modules are configured and function in thesame manner as described in the incorporated description of theApplicant's U.S. Provisional Patent Application No. 61/345,559 (DocketNo. KPM001PUS) and therefore detailed description of the platen andcapper modules is not provided herein.

The sled 603 is housed by the printer housing 101 so as to beselectively displaceable relative to the printhead 200 and so that mediafor printing is able to pass between the printhead 200 and the sled 603.Further, the maintenance modules are displaceable with respect to thesled which forms a support frame for the modules. The displacement ofthe sled selectively aligns each of the maintenance modules with theprinthead and the displacement of the aligned maintenance modules bringsthe aligned maintenance modules into operational position with respectto the printhead. This operation of the sled and displacement of themaintenance modules is described later and in further detail in theincorporated description of the Applicant's U.S. Provisional PatentApplication No. 61/345,559 (Docket No. KPM001PUS).

FIGS. 29-38G illustrate various exemplary aspects of the wiper module605. The wiper module 605 is an assembly of a body 607, a wiper element609, a transfer element 611, a drive mechanism 613 and a scraper element615. The body 607 is elongate so as extend along a length longer thanthe media width of the printhead 200. The wiper module 605 is housedwithin an elongate frame 617 of the sled 603 so as to be adjacent theplaten module 604, as illustrated in FIG. 29. The frame 617 has a base619 and sidewalls 621 projecting from the base 619 within which notches621 a are defined.

The notches 621 a removably receive retainer elements 622 at thelongitudinal ends of the platen module 604, retainer elements 623 at thelongitudinal ends of the body 607 of the wiper module 605, and retainerelements 686 at the longitudinal ends of the capper module 608. Thisengagement of the notches and retainers allows the platen, wiper andcapper modules to be held by the frame 617 in an unsecured, yetconstrained manner. That is, the modules effectively “float” within thesled, which facilitates the displacement of the modules relative to thesled. The wiper module 605 is assembled in the frame 617 so that thewiper element 609 faces the printhead 200 when the wiper module 605 isin its operational position.

The wiper element 609 is an assembly of a wiper roller 625 held on ashaft 627 by collars 629. The wiper roller 625 has a length at least aslong as the media width of the printhead 200 and is removably androtatably mounted to the body 607 by retention clips 631 at eitherlongitudinal end of a recess 633 formed by the base 619 and sidewalls621 of the body 607. The retention clips 631 are pivotally mounted tothe body 607 so as to provide a simple mechanism for removing andreplacing the wiper roller 625 when required.

The wiper roller 625 is caused to rotate through rotation of the shaft627 by the drive mechanism 613. This rotation is achieved through thecooperation of a wiper gear 635 fixedly mounted on one end of the shaft627 with a drive gear train 637 of the drive mechanism 613. The gears ofthe gear train 637 are rotatably mounted to the body 607 by a manifold639 and cooperate with a motor gear 641 of a motor 643 of the drivemechanism 613. The motor 643 is mounted to the body 607 and constitutesan on-board motor of the wiper module 605. The rotation of the wiperroller 625 is used to wipe ink from the printing face of the printhead200, as discussed in detail later.

The transfer element 611 has a non-porous transfer roller 645 which hasa length as long as the length of the wiper roller 625 and is eitherintegrally formed with pins 647 at either longitudinal end or mounted ona shaft 647. The transfer roller 645 is removably and rotatably mountedto the body 607 at either longitudinal end of the recess 633 by engagingthe pins or shaft 647 within corresponding holes 607 a in the body 607.In this assembled arrangement, removal of the transfer roller 645 ispossible upon removal of the wiper roller 625 from the body 607.However, other relative mounting arrangements are possible in which thetransfer roller is accessible independent of the wiper roller.

The transfer roller 645 is caused to rotate by the drive mechanism 613.This rotation is achieved through the cooperation of a transfer gear 649fixedly mounted on one of the pins 647 or one end of the shaft 627 withthe gear train 637 of the drive mechanism 613. This rotation of thetransfer roller 645 is used to clean the wiper roller 625, as discussedin detail later.

The on-board motor 643 of the wiper module 605 is powered through aflexible connection 649 with a power coupling 651 mounted on the frame617 of the sled 603 which is coupled with a power supply (not shown) ofthe printer 100 under control of the control electronics 802.

As the wiper module 605 is lifted from the frame 617 of the sled 603into its operational position at which the wiper roller 605 contacts theprinting face of the printhead 200, position sensors on the printerhousing 101 which communicate with the control electronics 802 sense thelifted position of the wiper module 605. One of ordinary skill in theart understands possible arrangements of such position sensors, so theyare not discussed in detail herein. This sensing of the lifted positionof the wiper module is used to control rotation of the wiper rollerprior to contact with the printing face of the printhead so that thewiper roller is already rotating as it contacts the printhead. Thisrotating contact reduces the amount of blotting of the nozzles of theprinthead by the wiper roller which could otherwise disturb the menisciwithin the nozzles and prevents un-desired deformation of the wiperroller about its circumference.

The rotational wiping of ink, other fluids and debris, such as mediadust and dried ink, from the printing face of the printhead 200 by thewiper roller 625 is primarily performed after priming of the printhead200 and after completion of a printing cycle, as described earlier.However, wiping can be performed at any time through selection of thewiper module 605.

The removal of ink and other fluids from the printing face of theprinthead 200 is facilitated by forming the wiper roller 625 of a porouswicking material which is compressed against the printing face so as toencourage wicking of the fluid into the wiper roller 625, and theremoval of debris from the printing face is facilitated by the rotationof the wiper roller 625.

In the illustrated embodiment of FIG. 32, the wiper roller 625 has acompressible core 625 a mounted to the shaft 627 and a porous material625 b provided over the core 625 a. In the exemplary embodiment, thecore 625 a is formed of extruded closed-cell silicone or polyurethanefoam and the porous material 625 b is formed of non-woven microfiber.Using microfiber prevents scratching of the printing face, whilst usingnon-woven material prevents shedding of material strands from the wiperroller and into the nozzles of the printhead. The non-woven microfiberis wrapped about the core by a spiralling technique so that at least twolayers of the microfiber are present about the core with an adhesivebetween the layers. Using two or more layers provides sufficient fluidabsorption and compressibility of the porous material from the core,which aids fluid absorption, whilst spiralling reduces the possibilityof the porous material being unwrapped from the core during thehigh-speed rotation of the wiper roller.

The Applicant has found that the use of microfiber which is compressedagainst the printing face of the printhead whilst rotating themicrofiber, causes ink to be drawn from the nozzles into the microfiberby capillary action. The amount of ink drawn from the nozzles is not somuch that drying of the nozzles occurs, but is sufficient to remove anydried ink from within the nozzles.

In order to prevent to core from absorbing the fluid collected in themicrofiber, which could otherwise cause over-saturation of the wiperroller 625 leading to transfer of the absorbed fluid back to theprinthead 200, a hydrophobic film, such as pressure sensitive adhesive,is disposed between the core 625 a and the porous material 625 b.

Fluid and debris collected on the surface of the wiper roller 625 isfurther prevented from being transferred back to the printing face byarranging the transfer roller 645 in contact with the wiper roller 625.The transfer roller 645 is arranged to contact the outer porous material625 b of the wiper roller 625 along the elongate length of the wiperroller 625 on a vertical circumferential region of the wiper rollerbelow the upper circumferential region of the wiper roller whichcontacts the printing face of the printhead 200, as illustrated in thecut-away partial detailed view of FIG. 33. Further, the transfer roller645 is preferably formed as a smooth cylinder of solid material, such assolid steel, stainless steel, or other metal or plated metal, so long asthe material is resistant to corrosion, particularly in inkenvironments, and is durable. Such a smooth metallic transfer roller 645can be machined to integrally include the pins 647.

This smooth and solid form of the transfer roller 645 and its contactwith the wiper roller 625 causes removal of fluid and debris from thewiper roller 625 by capillary action through the porous material 625 b,compression of the compressible core 625 a of the wiper roller 625,preference of fluid to move to areas of less saturation and the shear ofthe wiper and transfer rollers 625,645 provided by their rotatedcontact. The fluid removed from the wiper roller 625 drains undergravity into a drainage area 653 in the base 619 of the sled 603 throughholes 607 b in the body 607 of the wiper module 605, as is illustratedin FIG. 33 and as discussed in more detail later.

In the illustrated embodiment, the wiper and transfer rollers are gearedtogether through the driven gear train of the drive mechanism to rotatein the same direction, however other geared arrangements are possible inwhich the wiper and transfer rollers rotate in opposite directions, solong as the transfer roller exerts contact pressure on the compressiblewiper roller in a region of wiper roller which is rotationally returningto the upper circumferential region of the wiper roller in therotational direction of arrow A illustrated in FIG. 33. That is, thetransfer roller is positioned upstream of the rotational wipingdirection of the wiper roller. This positional arrangement ensures thatfluid and particles are removed by the transfer roller from portions ofthe wiper roller prior to those portions re-contacting the printhead.

The cleaning of the wiper roller by the transfer roller can also beeffected when the wiper module is not in its operational position forwiping the printhead, i.e., the wiper module is in the non-lifted (home)position in the sled 603, since the on-board motor 643 and drive train637 of the wiper module 605 can be operated in any operative ornon-operative position of the wiper module.

The scraper element 615 has a scraper or doctor blade 655 which has alength as long as the length of the transfer roller 645 and is mountedwithin the recess 633 of the body 607 so as to contact the transferroller 645. The doctor blade 655 is formed from a thin sheet ofresilient material, preferably steel or Mylar, however other materialswhich are inert to ink and other printing fluids can be used. The doctorblade 655 has a cantilevered section 655 a so as to form a sprungsqueegee. The free end of the cantilevered section 655 a contacts theouter surface of the transfer roller 645 to wipe the transfer roller 645clean as the transfer roller 645 rotates thereagainst.

The doctor blade 655 is arranged to contact the transfer roller 645along the elongate length of the transfer roller 645 on a verticalcircumferential region of the transfer roller below the uppercircumferential region of the transfer roller which contacts the wiperroller 625, as illustrated in the cut-away partial detailed view of FIG.33. The cleaning of the transfer roller by the thus arranged scraperelement 615 provides a newly clean transfer roller surface to be exposedto the wiper roller surface. Like the fluid transferred from the wiperroller 625, the fluid removed from the transfer roller 645 drains undergravity into the drainage area 653 in the base 619 of the sled 603.

FIGS. 34 and 35 illustrate various exemplary aspects of a displacementmechanism 700 for the modular sled 603. The displacement mechanism 700is similar to that described in incorporated description of theApplicant's U.S. Provisional Patent Application No. 61/345,559 (DocketNo. KPM001PUS) and therefore the same reference numerals are used hereinwhere suitable.

The displacement mechanism 700 is used to provide the selectivedisplacement of the sled 603 relative to the printer housing 101 and theprinthead 200 which selectively aligns each of the maintenance moduleswith the printhead. In the illustrated embodiment, the displacementmechanism 700 is a dual rack and pinion mechanism, having a rack 702 ateither elongate end of the sled 603, which are aligned with the mediatravel direction when sled 603 is installed in the printer 100, and apinion gear 704 at either end of a shaft 706, which is rotationallymounted to the printer housing 101 so as to be aligned with the mediawidth direction. The sled 603 is mounted to the printer housing 101 atthe racked ends through sliding engagement of rails 708 on the sled 603with linear bushings 710 mounted on the printer housing 101 (omitted inFIG. 35).

One end of the shaft 706 has a drive gear 714 coupled to a motor 716 viaa gear train 718. The motor 716 is controlled by the control electronics802 to drive rotation of the shaft 706 via the coupled gears therebysliding the sled 603 along the linear bushings 710. Selectivepositioning of the sled 603 to align the modules with the printhead isachieved by providing position sensors which communicate with thecontrol electronics. One of ordinary skill in the art understandspossible arrangement of such position sensors, so they are not discussedin detail herein.

The use of the dual rack and pinion mechanism for translating the sledrelative to the printhead, provides un-skewed and accurate displacementof the sled, which facilitates true alignment of the modules with theprinthead. Other arrangements are possible however, so long as thisun-skewed and accurate displacement of the sled is provided. Forexample, a belt drive system could be employed to displace the sled.

Once a selected one of the modules is aligned with the printhead, thealigned module is lifted from the sled into its respectiveafore-described operational position. Lifting of the modules isperformed by a lift mechanism 720, various exemplary aspects of whichare illustrated in FIGS. 36A-37 with respect to the wiper module 605.The lift mechanism 720 is similar to that described in incorporateddescription of the Applicant's U.S. Provisional Patent Application No.61/345,559 (Docket No. KPM001PUS) and therefore the same referencenumerals are used herein where suitable.

The lift mechanism 720 has rocker arms 722 which are pivotally mountedto a lower (first) housing section 103 of the printer housing 101 ateither sidewall 103 a of the lower housing section 103 at a pivot point724. Each rocker arm 722 has an arm portion 726 and a cam followerportion 728 defined on opposite sides of the respective pivot point 724.

The lift mechanism 720 also has a cam shaft 728 which is rotationallymounted between the sidewalls 103 a to be aligned with the media widthdirection. The cam shaft 728 has cam wheels 730 and 732 at respectiveends thereof. The cam shaft 728 is disposed so that an eccentric camsurface 730 a,732 a of each respective cam wheel 730,732 is in contactwith the cam follower portion of a respective one of the rocker arms722. The eccentric cam surfaces 730 a,732 a of the eccentric cams730,732 are coincident with one another, such that rotation of the camshaft 728 causes simultaneous and equal pivoting of the rocker arms 722through rotated contact of the eccentric cam surfaces 730 a,732 aagainst the cam followers 728. It is noted that in FIG. 36C theeccentric cam surface 732 a of the eccentric cam 732 is obscured fromview, FIGS. 44A, 44B and 46 of the previously incorporated in theApplicant's U.S. Provisional Patent Application No. 61/345,559 (DocketNo. KPM001PUS) illustrate the eccentric cam surface 732 a of theeccentric cam 732 more clearly.

This pivoting of the rocker arms 722 is constrained by the profile ofthe eccentric cam surfaces 730 a,732 a and by a spring 734 mountedbetween each rocker arm 722 and a base 101 a of the printer housing 101.In the illustrated embodiment, the springs 734 are compression springs,such that when the rocker arms 722 are pivoted to their lowestorientation the springs 734 are compressed, as illustrated in FIG. 36A,and when the rocker arms 722 are pivoted to their highest orientationthe springs 734 are at their rest position, as illustrated in FIG. 36B.

Rotation of the cam shaft 728 is provided by a motor 736 which ismounted on an outer surface of one of the sidewalls 103 a. The cam shaft728 projects through this sidewall 103 a so that the cam wheel 730 isdisposed on the internal side of the sidewall 103 a, with respect to theinternal disposition of the maintenance sled 603, and a worm gear 737 onthe cam shaft 728 is disposed on the external side of the sidewall 103a. The motor 736 is disposed on the sidewall 103 a so that a worm screw738 of the motor 736 contacts an outer circumferential surface 737 a ofthe worm gear 737 and meshes with ridges 737 b along the outercircumferential surface 737 a, as illustrated in FIG. 37. The threads ofthe worm screw 738 are helical, preferably right-handed with a 5°orientation and an involute profile. Likewise, the ridges 737 b arehelical, preferably right-handed with a 5° orientation and an involuteprofile.

Accordingly, rotation of the worm screw 738 through operation of themotor 736 under control of the control electronics 802 causes rotationof the cam wheel 737 which rotates the cam shaft 728. The rotatedposition of the eccentric cam surfaces 730 a,732 a is determined by anoptical interrupt sensor 739 mounted on the sidewall 102 a of theprinter housing 102 adjacent the other cam wheel 732. The opticalinterrupt sensor 739 cooperates with a slotted outer circumferentialsurface 732 b of the cam wheel 732, as illustrated in FIG. 36C, in amanner well understood by one of ordinary skill in the art.

When the sled 603 is being translated by the displacement mechanism 700to select one of the maintenance modules, the cams are controlled sothat the rocker arms 722 are at their lowest position. In this lowestposition, projections 740 of the arm portions 726 of the rocker arms722, which project toward the sled 603, are able to pass throughrecesses in the retainer elements of the modules, such that displacementof the sled 603 is not inhibited. Once the selected module is inposition, the cams are controlled so that the rocker arms 722 are movedto their highest position.

During this transition of the rocker arms 722 from the lowest to thehighest position, the projections 740 engage lift surfaces 742 of theretainer elements 622,623,686. This engagement causes the selectedmodule to be lifted with the rocker arms 722. The lift surfaces 742 areparallel to the base 619 of the sled 602 and are substantially flat.That is, in the illustrated embodiment the flat lift surfaces arehorizontal. The retainer elements 623 of the wiper module 605 havestiffening elements 749 at which the projections 740 of the rocker arms722 contact the lift surfaces 742. The stiffening elements 749 provideincreased rigidity to the retainer elements throughout lifting andlowering of the wiper module 605.

Like the wiper module described in the incorporated description of theApplicant's U.S. Provisional Patent Application No. 61/345,559 (DocketNo. KPM001PUS), the present wiper module 605 is configured to betranslated back and forth along the media travel direction so that thewiper roller 605 is rotationally wiped across the printing face of theprinthead 200. This displacement of the wiper module relative to theprinthead during wiping maximizes the amount of fluid and debris thatcan be wiped from the printhead. That is, a greater surface area of theprinting face can be wiped by moving the wiper module and wiping indifficult areas to wipe due to the different topographical levels on theprinting face provided by the different components can be achieved.

This translational wiping operation is achieved by displacing the sled603 whilst the wiper module 605 is in its lifted (wiping) position withthe wiper roller 625 contacting the printhead 200 and rotating underdrive of the drive mechanism 613. As is illustrated in FIG. 36B, thenotches 621 a in the sidewalls 621 of the sled frame 617 are dimensionedso that, in the wiping position, the retainer elements 623 of the wipermodule 605 do not leave the constraint of the notches 621 a.Accordingly, as the sled 603 is displaced the wiper module 605 is alsodisplaced in the same manner.

The on-board motor 643 of the present wiper module 605 allows retainedconnection to the power supply of the printer 100 through the flexibleconnection 649 in a large range of lifted and translated positions ofthe wiper module 605. This large range of translated wiping enableswiping of only a selected surface area of the printing face of theprinthead up to wiping of the entire surface area of the printing facethereby providing an effective total cleaning operation of theprinthead.

Exemplary translated wiping motions of the wiper module 605 areillustrated in the schematic views of FIGS. 38A-38G. In FIG. 38A, thewiper module is lifted in direction I so that the rotating wiper roller625 is brought into wiping contact with the printing face. In FIG. 38B,the sled 603 is translated in direction II with the wiper roller 625 inconstant rotating contact with the printing face. In FIG. 38C, the wipermodule 605 is returned to its home position in the sled 603 in directionIII from the translated position of FIG. 38B. In FIG. 38D, the sled 603having the wiper module 605 in its home position is translated indirection IV. In FIG. 38E, the sled 603 is translated in direction Vwith the wiper roller 625 in constant rotating contact with the printingface. In FIG. 38F, the wiper module 605 is returned to its home positionin the sled 603 in direction VI from the translated position of FIG.38E. In FIG. 38G, the sled 603 having the wiper module 605 in its homeposition is translated in direction VII.

As is described later in relation to FIG. 40, in terms of the directionof media transport for printing provided by the media handling system900, direction VII of FIG. 38G is the media transport direction anddirection IV of FIG. 38D is opposite to the media transport direction.Accordingly, the right-hand side of the each of the schematicsillustrated in FIGS. 38A-38G is defined as the “upstream” side of theprinthead 200 and the left-hand side of the each of the schematicsillustrated in FIGS. 38A-38G is defined as the “downstream” side of theprinthead 200.

The control electronics 802 can be programmed to define certaincombinations of these translated wiping motions of FIGS. 38A-38G so asto provide differently defined wiping routines of the maintenance system600. Some exemplary wiping routines are now described, however manyother wiping routines could be defined depending on the printingapplication of the printer 100.

A basic wiping routine is defined as a combination of the translatedwiping motions of FIGS. 38A-38C in the following order:

-   (1) the motion of FIG. 38A is executed with the sled positioned so    that the wiper roller is aligned with the printhead ICs of the    printhead and the wiping contact of the wiper roller on the    printhead ICs is maintained for two or three rotations of the wiper    roller so that the wiper roller dwells at the nozzles of the    printhead ICs;-   (2) the motion of FIG. 38B is executed so that the wiper roller is    translated just off the downstream edge of the printhead ICs; and-   (3) the motion of FIG. 38C is executed so that the wiper roller    moves back to its home position in the sled whilst still rotating,    which cleans the wiper roller through the afore-described action of    the transfer roller and the scraper.

This basic wiping routine reduces ink contamination by drawing outcontaminated ink from the nozzles due to the slight dwell of the wiperroller on the printhead ICs, clears debris and fibers from the nozzlesdue to the translated wiping over and off the printhead ICs, and therebyrevives non-ejecting nozzles.

An exemplary full-face wiping routine is defined as a combination of thetranslated wiping motions of FIGS. 38A-38F in the following order:

-   (1) the motion of FIG. 38A is executed but the wiper roller is not    dwelled at the printhead ICs;-   (2) the motion of FIG. 38B is executed so that the wiper roller is    translated off the downstream edge of the printhead ICs and over the    entire downstream side of the printing face of the printhead;-   (3) the motion of FIG. 38C is executed so that the wiper roller    moves to its home position in the sled whilst still rotating, which    cleans the wiper roller through the afore-described action of the    transfer roller and the scraper;-   (4) the motion of FIG. 38D is executed until the wiper roller is    aligned with the printhead just off the upstream edge of the    printhead ICs;-   (5) the motion of FIG. 38A is executed so that the wiper roller    makes wiping contact with the printing face in the aligned position    of (4);-   (6) the motion of FIG. 38E is executed so that the wiper roller is    translated over the entire upstream side of the printing face of the    printhead; and-   (7) the motion of FIG. 38F is executed so that the wiper roller    moves to its home position in the sled whilst still rotating, which    cleans the wiper roller through the afore-described action of the    transfer roller and the scraper.

This full-face wiping routine clears condensation, ink puddles andfibers that may have accumulated on any area of the printing face of theprinthead. The full-face wiping routine is not intended to revive thenozzles, however the basic and full-face wiping routines can be used inconjunction with one another, or with any other wiping routine, toachieve this.

As discussed above, the fluid captured by the wiper module 605 drainsinto the sled 603. Fluid captured by the platen and capper modulessimilarly drains into the sled 603 in the manner described in theincorporated description of the Applicant's U.S. Provisional PatentApplication No. 61/345,559 (Docket No. KPM001PUS). As illustrated inFIG. 33, the sled 603 has the drainage areas 632, 653 and 696 in thebase 619. The drainage areas are defined in the base 619, such as bymolding, to provide discrete paths to a hole 657 in the base 619, fromwhich the fluid in the drainage areas is able to leave the sled 603. Thehole 657 in the sled 603 may be aligned with a slot or aperture in thebase 101 a of the printer housing 101 so that the drained fluid isrouted to the fluid collection tray 601 which collects and stores thedrained fluid. The discrete paths are defined by walls 619 a which actas drainage ribs which constrain the fluid in the sled 603 from freemovement during displacement of the sled 603. In this way, the capturedfluid is able to drain from the sled without being ‘sloshed’ around thesled which could cause the fluid to be ‘splashed’ onto the printhead.The sled 603 may be molded from a plastics material, such as a 10% glassfibre reinforced combination of polycarbonate and acrylonitrilebutadiene styrene (PC/ABS), with the walls 619 a integrally definedtherein.

The drainage area 653 receives fluid drained from the wiper module 605through the holes 607 b of the body 607, as illustrated in FIGS. 32 and33. In the manner described in the incorporated description of theApplicant's U.S. Provisional Patent Application No. 61/345,559 (DocketNo. KPM001PUS), the drainage area 632 receives fluid drained from theplaten module 604 and the drainage area 696 receives fluid drained fromthe capper module 608 engagement of a valve 698 of the capper module 608and a projection 699 on the base 619 of the sled 603.

As illustrated in FIG. 39, the fluid collection tray 601 is an assemblyof a tray 661 and a fluid storage pad 663 of an absorbent material whichis exposed within the tray 661. The fluid collection tray 601 isremovably received in the printer housing 101 so that replacement oremptying of the fluid storage pad 663 is possible. In particular, thetray 661 may be slid into position directly beneath the sled 603 in theprinter housing 101 so that the drained fluid flows into the fluidstorage pad 663 under gravity. Alternatively, as illustrated in FIG. 6,the tray 661 may be slid into position beneath the supply cartridges 301and a shaped wicking element (not shown) between the sled 603 and thefluid storage pad 663 so that the drained fluid flows into the wickingelement under gravity and then flows into the fluid storage pad 663under capillary action and gravity.

The afore-described components of the maintenance system 600 provide ameans of maintaining the printhead 200 and fluid distribution system 300in operational condition by maintaining the printing environment aboutthe printhead 200 free from unwanted wet and dried ink and debris. Inparticular, the linear translating sled with selectable maintenancemodules provides a simple and compact manner of maintaining thestationary, full media width printhead. Employing a wiper module whichis fully translatable whilst wiping the printhead provides enhancedcleaning.

The media handling system 900 is now described. FIGS. 6, 7 and 39-45Billustrate various exemplary aspects of the media handling system 900.

The media handling system 900 is defined within the printer 100 totransport and guide media past the printhead 200 along the direction ofarrow B illustrated in FIG. 40 (i.e., the media transport direction)between the lower housing section 103 and an upper (second) housingsection 105 of the printer housing 101. The upper housing section 105 ishingedly attached to the lower housing section 103 at hinge elements 107and is latched to the lower housing section 103 at latch elements 109.In the illustrated embodiment, the hinge elements 107 are linked by asprung shaft 107 a, however other arrangements are possible. This hingedengagement of the lower and upper housing sections 103,105 allows accessto the media handling system 900 so as to easily clear media jams andthe like during printing.

The media handling system 900 has a driven roller assembly 901 definedin the lower housing section 103. The driven roller assembly 901 has aseries of driven media transport rollers rotationally mounted to thesidewalls 103 a of the lower housing section 103, as illustrated mostclearly in FIG. 41. The series of driven media transport rollers includean entry roller 903 and an input roller 905 disposed on the upstreamside of the printhead 200 with respect to the media transport directionand an exit roller 907 disposed on the downstream side of the printhead200 with respect to the media transport direction.

The entry roller 903 receives media which is supplied either manually orautomatically and is rotated to feed the received media to the inputroller 905. The media handling system 900 of the present exemplaryembodiment is provided for handling web media, preferably label webmedia on which label information is printed by the printhead 200, from amedia roll which is either externally provided to the printer 100 orreceived within the housing 101 of the printer 100. Having said this,the media handling system 900 of the present exemplary embodiment isalso applicable to handling discrete sheet media. Mechanisms andarrangements for supplying such web or sheet media are well understoodby one of ordinary skill in the art.

The input roller 905 receives the media fed from the entry roller 903and is rotated to feed the received media to the printhead 200 forprinting. The exit roller 907 receives the media fed from the inputroller 905 via the printhead 200 and is rotated to transport the mediareceived from the printhead 200. In relation to web media, the exitroller 907 transports the web media to a cutter mechanism or the likewhich is either externally provided to the printer 100 or receivedwithin the housing 101 of the printer 100 and which separates theprinted portion of the web media from the unprinted portion of the webmedia. The arrangement and operation of such a cutter mechanism is wellunderstood by one of ordinary skill in the art.

The rotation of the driven rollers 903-907 is driven by a drivemechanism 909 of the driven roller assembly 901 located at one of thesidewalls 103 a of the lower housing section 103. The drive mechanism909 has a drive motor 911 and a drive belt 913 which is looped about adrive shaft of the motor 911 and each of the driven rollers 903-907 soas to impart the rotational driving force of the motor 911 to each ofthe rollers 903-907 in a manner well understood by one of ordinary skillin the art. In this way, each of the driven rollers 903-907 is driven atthe same rotational speed which ensures smooth movement of the mediapast the printhead 200. In the illustrated embodiment all of the drivenrollers are driven using a single drive belt, however other arrangementsare possible in which one driven roller is driven by the drive belt, ormultiple drive belts are provided for the respective driven rollers.

The motor 911 is preferably a bi-directional motor so that uponcessation of printing and separation of the printed media from the webby the cutting mechanism, the unprinted web media is able to beretracted to a position upstream of the printhead 200. This enables thewiper and capper modules 605,608 of the maintenance system 600 to bebrought into operational position relative to the printhead 200 in themanner described earlier herein and in the incorporated description ofthe Applicant's U.S. Provisional Patent Application No. 61/345,559(Docket No. KPM001PUS).

Suitable tension in the flexible drive belt 913 which ensures that thedriven rollers 903-907 are reliably driven at the same rotational speed,is maintained by a tensioning assembly 915 located between the motor 911and one of bushings 917 about which the drive belt 913 is run. Asillustrated in the cut-away partial detailed view of FIG. 41, thetensioning assembly 915 has a tensioning member 919 which is pivotallymounted to the sidewall 103 a at a pivot pin 921. A helical torsionspring 923 is disposed about the pivot pin 921 so that an arm 923 a ofthe spring 923 exerts torsional force against a tab 103 b projectingfrom the sidewall 103 a. This sprung arrangement biases the tensioningmember 919 in the direction of the drive belt 913. The drive belt 913 isdimensioned so that this biased contact of the tensioning member 919causes any slack in the drive belt 913 about the motor shaft, drivenrollers 903-907 and bushings 917 to be removed. In the illustratedembodiment, the spring is a helical torsion spring, however other typesof springs, such as a compression spring, or other biasing means can beused so long as the tensioning member is biased toward the drive belt.

The tensioning member 919 has a slotted arm 925 through which a lockingscrew 927 is screwed into a hole 103 c in the sidewall 103 a, asillustrated in FIG. 42. The slot within the slotted arm 925 is curved soas to form a lunette, such that the hole 103 c in the sidewall 103 a isexposed through the curved slot throughout rotation of the tensioningmember 919 about its pivot point. Accordingly, the locking screw 927 canbe fixed within the hole 103 c in any rotated position of the tensioningmember 919 so as to lock the tensioning member 919 in that rotatedposition.

This arrangement of the tensioning member allows the amount of tensionin the drive belt to be selected by selectively locking the rotatedposition of the tensioning member. This selection provides tolerance ofstretching in the drive belt over time, which would otherwise causeslackening of the drive belt, since the rotated position of thetensioning member can be changed as desired. In the illustratedembodiment, a locking screw is used, however other locking means arepossible so long as the rotated position of the tensioning member can bedynamically selected.

The Applicant has found that when the locking screw 927 is fastenedagainst the slotted arm 925 of the tensioning member 919, the rotationalforce of the locking screw 927 can be imparted to the tensioning member919 causing undesired rotation of the tensioning member 919. Thisrotation is undesired because the ultimate locked rotated position ofthe tensioning member ends up being different than the desired rotatedposition. In order to prevent this over-rotation of the tensioningmember 919, a brace member 929 is provided between the slotted arm 925and locking screw 927, as illustrated in the cut-away partial detailedview of FIG. 41.

The brace member 929 is elongate and has pins 929 a at either end whichare snugly received within respective holes 103 d of the sidewall 103 a,as illustrated in FIG. 42, such that the brace member 929 is unable torotate relative to the sidewall 103 a. Thus, as the locking screw 927 isscrewed into position the brace member 929 is forced against the slottedarm 925 of the tensioning member 919, however the rotational force ofthe locking screw 927 is not imparted to the slotted arm 925.

The media handling system 900 further has a media guide assembly 931defined in the lower housing section 103. The media guide assembly 931has a series of guide members 933 which each extend along the mediawidth direction of the printhead 200. The individual guide members 933are located between the driven media transport rollers 903-907 bothupstream and downstream of the printhead 200 with respect to the mediatransport direction, as illustrated most clearly in FIG. 41. The guidemembers 933 provide platens along which the fed media is guided.

In FIG. 41, the platen module 604 of the maintenance system 600 isillustrated in its operational (lifted position). As can be seen, eachguide member 933 has a series of ribs 933 a which align and interlockwith the ribs 626,628 of the platen module 604. To this end, the ribs626,628 of the platen module 604 of the present embodiment are formed toextend about the edges of the platen module 604 (see FIGS. 29 and 30),which is a slight difference from the ribs of the platen moduledescribed in the incorporated description of the Applicant's U.S.Provisional Patent Application No. 61/345,559 (Docket No. KPM001PUS).This interlocked arrangement of the media guiding ribs ensures that themedia is smoothly transported past the printhead 200.

The media handling system 900 further has a pinch roller assembly 935defined in the upper housing section 105 so as to extend across themedia width direction of the printhead 200. As illustrated in FIG. 42,the pinch roller assembly 935 has a (first) series of entry pinchrollers 937 which engage with, and provide a pinched nip for the mediaalong, the entry roller 903 and a (second) series of input pinch rollers939 which engage with, and provide a pinched nip for the media along,the input roller 905 when the lower and upper housing sections 103,105are hinged into the closed position, illustrated in FIG. 40. Each seriesof pinch rollers 937,939 therefore defines an idler roller for thecorresponding driven roller.

Each pinch roller 937,939 is part of a pinch element 941 of the pinchroller assembly 935. The pinch elements 941 are held between an elongatesupport plate 943 and either an elongate entry (first) pinch housing 945or an elongate input (second) pinch housing 947 of the pinch rollerassembly 935 so as to serially extend across the media width directionof the printhead 200. The support plate 943 is fastened to an elongatemounting plate 949 by fasteners 951. The mounting plate 949 securelymounts the pinch roller assembly 935 to sidewalls 105 a of the upperhousing section 105, as illustrated in FIG. 40.

As illustrated in FIG. 43, the pinch housings 945,947 are held to themounting plate 949 by tabs 949 a so that bushes 949 b of the mountingplate 949 ride within slots 953 in the pinch housings 945,947 (as isparticularly illustrated for the entry pinch housing 945 in FIG. 43).Further, the pinch housings 945,947 are linked to the support plate 943by springs 955 at either longitudinal end of the pinch housings 945,947and the support plate 943. By this arrangement, the pinch housings945,947 are constrained by the stationary support plate 943 so as to bemovable with respect to the mounting plate 949. The advantages of thisrelative movement of the pinch housings is described later. Whilst thesprings 955 are illustrated as compression springs, other types ofsprings, such as leaf springs, or other types of biasing means can beused so long as the pinch housings are able to move relative to themounting and support plates.

An axle 937 a of each of the pinch rollers 937 is rotatably held withina corresponding slot 957 of the pinch housing 945 by a lever member 959of the respective pinch element 941. This is illustrated most clearly inFIG. 43 in which one of the lever members 959 is omitted. Similarly, anaxle 939 a of each of the pinch rollers 939 is rotationally held withina corresponding slot 957 of the pinch housing 947 by a lever member 959of the respective pinch element 941.

As illustrated in FIG. 44, each lever member 959 has a rod 959 a at oneend, which is pivotally supported by a corresponding hook 943 a of thesupport plate 943, a yoke 959 b at the other end, which receives theaxle 937 a,939 a of the corresponding pinch roller 937,939 and which hasa longer arm 959 c held within the corresponding pinch housing 945,947by a hook 961 (see FIG. 42), and an aperture 959 d between those ends,in which a corresponding spring 963 is received to be compressed betweenthe lever member 959 and the mounting plate 949.

By this arrangement, the pinch rollers 937,939 are biased by the springs963 into contact with the respective entry and input rollers 903,905whilst being able to allow media to pass therebetween, within theconstraint of the relative dimensions of the yoke arms 959 c of thelever members 959 and the hooks 961 of the pinch housings 945,947.

In the illustrated embodiment, the springs of the lever members arecompression springs, however other types of springs, such as leafsprings, or other types of biasing means can be used so long as thepinch rollers are biased into contact with the entry and input rollers.Further, in the exemplary embodiment the entry and input rollers (andexit rollers) are preferably grit rollers and the pinch rollers arepreferably formed of a material, such as hard rubber, which is resistantto wear from the grit entry and input rollers whilst providingsufficient grip for the media. However, one of ordinary skill in the artunderstands that other materials are possible for the driven and pinchrollers, so long as sufficient nip and grip for the media is provided.

Since the lever members are securely held by the support plate but arenot fastened to either the pinch rollers or the pinch housings, andsince the pinch rollers are supported within the slots of the pinchhousings without being fixed thereto, the pinch rollers effectively“float” within the lever members such that the pinch rollers are able tomove with the pinch housings relative to the support plate. Theadvantages of this “floating” of the pinch rollers and the relativesliding of the pinch housings are now described.

As the upper housing section 105 is hinged between the open and closedpositions relative to the lower housing section 103 throughout operationof the printer 100, it is possible that the required alignment of thedriven and pinch rollers may be unreliably maintained which may causemedia transport problems, such as misfeeds and media jams. In order tomaintain correct alignment throughout operation the pinch rollerassembly 935 must be consistently aligned with the driven rollerassembly 901 each time the upper housing section 105 is returned to theclosed position with the lower housing section 103.

This is achieved by engaging the pinch housings 945,947 with bearingmembers 967 which rotationally mount the entry and input rollers 903,905to the sidewalls 103 a of the lower housing section 103. In particular,as illustrated in FIGS. 45A and 45B, alignment pins 945 a,947 a areprovided at each longitudinal end of the pinch housings 945,947 whichengage with slots 965 in the bearing members 967. The bearing members967 are configured to be fixedly mounted to the sidewalls 103 a so thatonce the alignment pins 945 a,947 a and the bearing slots 965 areengaged the pinch rollers 937,939 are immovable with respect to theentry and input rollers 903,905. By this arrangement, the alignment pinsof the pinch housings can be effectively engaged with the lower housingsection of the printer.

The slots 965 of the bearing members 967 have sloped outer surfaces 965a which funnel the alignment pins 945 a,947 a into the slots 965 as theupper housing section 105 is rotated into its closed position on thelower housing section 103. This engagement of the pins and the bearingslots is facilitated by the floating arrangement of the pinch housings,since the pinch housings slide relative to the fixedly mounted supportplate as the pins are funnelled into the slots. Accordingly, the slidingmovement of the pinch housings relative to the support plate and theyoked engagement of the lever members and pinch rollers provide analignment adjustment mechanism for maintaining alignment between thedriven and pinch rollers.

While the present invention has been illustrated and described withreference to exemplary embodiments thereof, various modifications willbe apparent to and might readily be made by those skilled in the artwithout departing from the scope and spirit of the present invention.Accordingly, it is not intended that the scope of the claims appendedhereto be limited to the description as set forth herein, but, rather,that the claims be broadly construed.

1. A system for reducing ink color mixing effects in a printer, thesystem comprising: a printhead having multiple ink color channelsmounted to a housing of the printer at a first level; and a plurality ofink supply cartridges mounted to the printer housing so as to befluidically connected to the printhead and stacked in an array having aplurality of rows defining a plurality of levels which are lower thanthe first level, wherein the plurality of ink supply cartridges includeat least one black ink supply cartridge which supplies black colored inkto a black ink color channel of the printhead, the black ink supplycartridge being disposed at the lowest level defined by the array.
 2. Asystem according to claim 1, wherein the plurality of ink supplycartridges include two black ink supply cartridges which supplies blackcolored ink to the black ink color channel of the printhead, a cyan inksupply cartridge which supplies cyan colored ink to a cyan ink colorchannel of the printhead, a magenta ink supply cartridge which suppliesmagenta colored ink to a magenta ink color channel of the printhead anda yellow ink supply cartridge which supplies yellow colored ink to ayellow ink color channel of the printhead.
 3. A system according toclaim 2, wherein the array has three rows and three columns, the blackink supply cartridges being disposed at the lowest row in the first andthird columns of the array, the magenta and cyan ink supply cartridgesbeing disposed at the middle row in the first and third columns of thearray and the yellow ink supply cartridge being disposed at the highestrow in the second column of the array.